Technical

Report
COPPER • BRASS • BRONZE

The U.S. Copper-base

Scrap Industry and Its
By-products – 2007

Copper Development Association Inc.

A1309-07/08
The U.S. Copper-base Scrap Industry
And Its By-products

An Overview

Eighth Edition
January 2008

Copper Development Association Inc.

260 Madison Avenue
New York, NY 10016
(212) 251-7200
www.copper.org

Janice L. Jolly
Dayton, Maryland

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 PREFACE
The purpose of this report is to provide a brief background on the U.S. copper and copper alloy
secondary processing industry. It is felt that policy and decision-makers can use a ready
reference on an industry that is generally so little understood. The industry has undergone many
changes over the past few decades and has been in decline over much of that period. During the
research, it was discovered that, since the mid-1990s, several problems as well as possible
solutions for some of these problems became apparent. While the coverage is not
comprehensive, a brief mention is made of them. The secondary industry and the Government
agencies most concerned with legislation affecting the collection, processing and markets for
scrap are both working to overcome some of the current difficulties. Nevertheless, for some
sectors of the secondary copper industry, the past few years have been particularly difficult, given
the restrictions within which they have operated, the potential for new restrictions, and the current
copper market.

The author would particularly like to thank those in the industry who were kind enough to host
informative visits to their plants and to provide much of the information contained in this report. In
particular, Alan Silber of RECAP, who was of tremendous help in outlining the original report.
Daniel Edelstein, Copper Specialist with the U.S. Geological Survey, also provided substantial
help and advice. The International Copper Study Group, was of great assistance in providing
world copper industry statistics. The research for this report was supported by the Copper
Development Association. This eighth edition presents updated data tables and observations
made since the first report was written in 1999.

ABOUT THE AUTHOR

Janice L.W. Jolly has had more than 35 years experience in both the primary and secondary
copper industries. She first spent 14 years as a research geologist with the U.S. Geological
Survey and with Roan Selection Trust in the Zambian Copperbelt. Following this, she served 18
years as a foreign mineral and commodity specialist with the U.S. Bureau of Mines. She was the
copper commodity specialist for the Bureau of Mines for more than 10 years, responsible for that
agency’s data collection and reports on copper and copper scrap. She also worked briefly with
the Armed Services Committee of the House of Representatives and the World Bank. She is
author of many articles and reports on copper and copper scrap and is especially familiar with the
statistics relating to these subjects. She spent almost 4 years in Portugal with the International
Copper Study Group (ICSG) as its first Chief Statistician and was instrumental in establishing the
ICSG statistical collection and publishing effort on copper. She retired from the U.S. Bureau of
Mines in 1993 and from the International Copper Study Group in 1997. Currently a copper
industry consultant, she resides in Dayton, Maryland.

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 TABLE OF CONTENTS
EXECUTIVE SUMMARY .................................................................................................................................. 1

CHAPTER 1 — INDUSTRY PERSPECTIVES

Global Industry Perspective ................................................................................................... 5
World Copper Consumption and Production ............................................................ 5
World Trade in Copper Scrap ................................................................................... 7
World Production and Trade in Copper Alloy Ingot ................................................ 11
Domestic Industry Perspectives ........................................................................................... 12
Domestic Uses for Copper ..................................................................................... 12
U.S. Consumption of Copper.................................................................................. 12
U.S. Trade in Copper and Copper Alloy Scrap ...................................................... 14
U.S. Export Controls on Scrap ............................................................................... 15
Products and By-products Produced from Scrap ................................................................. 16
Wrought Copper and Copper Alloys ....................................................................... 16
Brass and Bronze Ingots ........................................................................................ 16
Refined Copper ...................................................................................................... 17
Copper Anodes for Plating ..................................................................................... 17
Black Copper .......................................................................................................... 17
Copper Chemicals and Powders ............................................................................ 17
Secondary Copper By-products ............................................................................. 19
Baghouse Dusts ..................................................................................................... 19
Other Metal Recovery............................................................................................. 20
Items that Go to the Landfill.................................................................................... 20
Description of the U.S. Secondary Industry ......................................................................... 20
Brass Mills .............................................................................................................. 22
Foundries................................................................................................................ 22
Ingot Makers ........................................................................................................... 22
Secondary Smelters and Refiners .......................................................................... 22
Hydrometallurgical Plants ....................................................................................... 22
Metal Finishing Facilities ........................................................................................ 23
Flow Materials ...................................................................................................................... 23
Summary of Scrap Flow ......................................................................................... 23

CHAPTER 2 — OVERVIEW OF SCRAP SOURCES AND TYPES

Scrap Sources and Types .................................................................................................... 24
EPA Secondary Product Definitions..................................................................................... 24
Consumption by Scrap Type ................................................................................................ 25
Volumes of Scrap Generated ............................................................................................... 27
Use of Home Scrap .............................................................................................................. 29
At Brass and Wire Mills .......................................................................................... 29
At Secondary Smelters and Refiners ..................................................................... 30
At Foundries ........................................................................................................... 30
Use of Purchased Scrap ...................................................................................................... 30
Life Cycles and the Theoretical Resource for Scrap ............................................................ 30
Resource Theory and Calculations ........................................................................ 31

CHAPTER 3 — OVERVIEW OF SCRAP PREPARATION, MELTING AND PROCESSING

Scrap Preparation ................................................................................................................ 38
Laboratory Testing ............................................................................................................... 39
Energy Use .......................................................................................................................... 39
For Scrap Preparation ............................................................................................ 40
Melting Scrap.......................................................................................................... 40
Scrap Melting and Processing ............................................................................................. 40
Melt Control ............................................................................................................ 41

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 Drosses and Dross Formation ................................................................................ 41
Melt Covers (Fluxes) .............................................................................................. 41
Use of Deoxidizers ................................................................................................. 42
Vapor Losses.......................................................................................................... 42
Particulate Matter and Fugitive Emissions ............................................................. 42
Furnaces .............................................................................................................................. 43
Arc Furnaces .......................................................................................................... 43
ASARCO Furnaces ................................................................................................ 43
Crucible Furnaces .................................................................................................. 44
Blast Furnace, Cupola ............................................................................................ 44
Reverberatory Furnaces ......................................................................................... 44
Converters .............................................................................................................. 45
Rotary Furnaces ..................................................................................................... 45
Low-frequency Induction Furnaces ........................................................................ 45
Sweating .............................................................................................................................. 45

CHAPTER 4 — ENVIRONMENTAL OVERVIEW

Basel Convention ................................................................................................................. 46
OECD Rulings ........................................................................................................ 46
CERCLA Overview............................................................................................................... 47
Hazard Ranking System (HRS) .............................................................................. 48
Resource Conservation and Recovery Act .......................................................................... 48
Toxicity Characteristic Leaching Procedure (TCLP) ............................................................ 48
Suggested Improvements for the TCLP ................................................................. 49
Multiple Extraction Procedure (MEP) ..................................................................... 50
Hazardous Wastes ............................................................................................................... 51
Toxic Release Inventory System (TRIS) and Other Databases ........................................... 51
Lead in the Workplace Directives (OSHA) ........................................................................... 51
Clean Air Act Ruling ............................................................................................................. 52

CHAPTER 5 — PROBLEMS AND SOLUTIONS

The Problems ....................................................................................................................... 54
Industry Solutions................................................................................................................. 55
Process Recovery Corp.......................................................................................... 56
Management Systems and ISO Standards ............................................................ 56
Government Solutions.......................................................................................................... 58

ILLUSTRATIONS:

CHAPTER 1 FIGURES
Figure 1. Price Spreads Between Refiners No. 2 Scrap
and U.S. Producers Refined Prices .............................................................................. 6
Figure 2. World Copper Recovery from All Sources and Percent Copper from Scrap .................... 7
Figure 3. World Consumption of Copper of Direct Melt and Refined Scrap, by Region .................. 8
Figure 4. Trade in Copper and Copper Alloy Scrap, by World Region ............................................ 9
Figure 5. U.S. Total Copper Consumption, Including All Scrap ..................................................... 10
Figure 6. Trends in U.S. Net Export and Consumption
of Copper in Copper-base Scrap ................................................................................ 11
Figure 7. U.S. Copper Alloy Ingot Production, by Ingot Group ...................................................... 14
Figiure 8. Trends in U.S. Copper Smelter and Refinery Capacities ................................................ 15
Figure 9. U.S. Copper and Copper Alloy Purchased Scrap Flow Chart ......................................... 18

CHAPTER 2 FIGURES
Figure 10. U.S. Copper and Copper Alloy Scrap Consumption, by General Alloy Group ................ 27

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 Figure 11. U.S. and World Scrap Resource, Pool of Copper Materials in Use ................................ 32
Figure 12. U.S. Copper Resource for Old Scrap, Pool of Copper Materials in Use ......................... 33
Figure 13. Cumulative Old Scrap Copper, In the United States ....................................................... 34
Figure 14. Relationships of Primary Copper and Old and New Scrap to U.S. Cumulative
Copper Resource Calculations ................................................................................... 35
Figure 15. U.S. Industrial Copper Consumption Trends and Response
to Major Historical Events .......................................................................................... 88

TABLES:

CHAPTER 1 TABLES
Table 1. LME, COMEX and U. S. Refined, Scrap and Ingot Prices ............................................... 60
Table 2. World Copper Consumption. Direct Melt and Refined Scrap, and Refined Copper
A. World Copper Recovery from All Sources ................................................................. 61
B. World Production of Refined Copper by Source ........................................................ 62
C. World Consumption of Copper in Direct Melt Scrap ................................................. 63
D. World Recovery of Copper from Copper-base Scrap, by Country and Area ............ 64
Table 3. World Copper and Copper Alloy Scrap Exports ............................................................... 65
Table 4. World Copper and Copper Alloy Scrap Imports ............................................................... 66
Table 5. World Production of Copper and Copper Alloy Ingots ...................................................... 67
Table 5A. World Production of Copper and Copper Alloy Foundry Products ................................... 68
Table 5B. Copper, Copper Alloy and Master Alloy Ingot Imports...................................................... 69
Table 5C. Copper, Copper Alloy and Master Alloy Ingot Exports ..................................................... 69
Table 6. U.S. and World Refined Copper Consumption and U.S. Copper From Scrap ................. 70
Table 6A. U.S. Cumulative Copper Calculations .............................................................................. 72
Table 6B. Estimation of the Recycling Input Ratio (RIR) and Recovery Ratio
for the United States .................................................................................................... 73
Table 7. U.S. Production of Refined Copper, by Source ................................................................ 74
Table 8. U.S. Exports and Imports of Copper and Copper Alloy Scrap .......................................... 75
Table 8A. U.S. Domestic Exports of Copper and Copper Alloy Scrap, by type ................................ 75
Table 9. U.S. Trade and Consumption of Copper Ash and Residues
and Zinc Products from Scrap.. .................................................................................... 76
Table 10. Ingots, Foundry Castings, Brass- and Wire-Mill Semis and Copper Sulfate
Production in the United States .................................................................................... 77
Table 11. Standard Designations for Cast Copper Alloys ................................................................ 77
Table 12. Copper Recovered from Scrap in the United States and Form of Recovery .................... 78
Table 13. List of U.S. Primary Brass and Tube Mills ........................................................................ 79
Table 14. List of U.S. Ingot makers, Secondary Smelters and Refiners, and Secondary
Chemical and Hydrometallurgical Plants ...................................................................... 80

CHAPTER 2 TABLES
Table 15. Copper and Copper Alloy Scrap Types, Showing General Range in Compositions ........ 81
Table 16. Principal U.S. Scrap Source Materials for Copper............................................................ 82
Table 17A. U.S. Copper Scrap and Copper Alloy Consumption ......................................................... 83
Table 17B. U.S. Copper Scrap and Copper Alloy Consumption ......................................................... 84
Table 18. Estimated Secondary By-products, by Plant-Type Sector ................................................ 85

CHAPTER 3 TABLES
Table 19. Particulate Emission Factors for Furnaces Used in Secondary Copper Smelting
and Alloying Process .................................................................................................... 86

APPENDIX A Historical Review of U.S. Export Controls on Copper-base Scrap ................................... 87

APPENDIX B Superfund Sites ................................................................................................................ 91
LIST OF REFERENCES ................................................................................................................................. 94

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EXECUTIVE SUMMARY severely impacted by surplus world copper
production, higher environmental compliance costs
Soaring world copper and copper scrap demand, and escalating scrap exports to competing nations.
particularly in Far Eastern countries, has continued to Lower copper prices and higher recovery costs from
be a prominent fact in recent years. Higher prices 1998 through 2003 created a cost squeeze that
followed the resulting supply shortages of the past caused the closing of all U.S. secondary smelters and
three years. Following the copper oversupply years of associated electrolytic refineries. Of the four
1999 through 2003, the world economic recovery was secondary smelting and two electrolytic refining firms
well underway in 2004 and copper prices reached a operating in 1996, none remained after 2001. Fire
high of about $1.50 per pound on the LME by year’s refining, which requires a better grade of scrap, held
end. World copper prices continued to rise through its own through much of the period, but was also
2007, with the LME spot copper price, at one point, affected by occasional cutbacks and closings. Plant
exceeding $4.00 per pound. The average LME grade closings also occurred in the ingot-making and
A price for 2006 and 2007 averaged about $3.05 and foundry sectors of the industry.
$3.23 per pound, respectively. In the United States,
the significant upturn in copper prices and widening The significant competition by foreign nations for
price differentials partially compensated for higher quality domestic scrap over the past 10 years has
secondary collection, processing and disposal costs. negatively impacted U.S. scrap dealers, scrap
Even so, scrap supplies were tight for most grades processors and users alike. The trend of higher
collected, owing to high domestic demand and exports of U.S. copper scrap has increased
increasingly higher exports. significantly since 1999. A temporary drop in U.S.
scrap exports in 2005 probably was partially owing to
World copper was in short supply through most of the threat from a short supply petition made to the
2005, 2006 and 2007. Shortages persisted despite U.S. Government in early 2004 as well as a move by
efforts by the major copper producers to bring mines the Chinese Government to tighten control on certain
back on stream during 2005 and to increase metal imports. Although the U.S. Government turned
production. Labor strikes, lower ore grades and other down the industry petition for control and monitoring of
production problems seemed to plague the industry. scrap exports, the U.S. scrap availability situation had
The supply/demand deficit for 2005 was 73,000 tons improved by year’s end 2004 for a short period. Some
according to the International Copper Study Group U.S. wire choppers reported significant pickup in
(ICSG). At the end of December 2006, total world activity and a return to profitability. However, by 2006,
copper inventories, were 1.1 million tons and were U.S. scrap exports continued at a high pace through
about 23% less than that required to supply the world 2007, and were more than double the export rate in
for one month. Owing to the release of unknown, but 1999.
apparently significant, quantities of copper from the
Chinese strategic stockpile, world copper supplies With higher copper prices, a tighter copper supply
were partially ameliorated during the latter part of situation and more lucrative price spreads, the U.S.
2006, and prices began to soften. By year’s end 2006, copper scrap processing industry started to look for a
visible world copper stocks were estimated by the better near term future. However, any new legislation
ICSG to be around 1.093 million tons, up by about that further controls and hinders the easy flow of
238,000 tons from that of year’s end 2005. These secondary materials between firms could cause a
inventories represented about 3 weeks of average further contraction of the industry. Without a basic
world copper consumption, still well below the four- domestic secondary-processing infrastructure, more
week level for world consumption that by many is valuable metals likely will reach the landfill as the
considered to be “normal”, or in balance. most reasonable remaining choice. Export is always
possible for the higher grades of scrap, but the lower-
In contrast, at the end of 2002, the accumulated world grade copper by-products, which might be traded
copper inventories represented well over two months domestically, could become less marketable.
of industry supply at average rates of consumption. In
an attempt to correct the oversupply situation during U.S. scrap processors and their U.S. customers
2002, several mines in Chile and the rest of the world (brass mills, ingot makers and foundries) remained at
cut back on production. By the middle of 2003, these a critical crossroad. Scrap supplies through 2006 and
cutbacks and the gradual recovery of world 2007 remained tight and some qualities were difficult
economies resulted in a draw down of copper stocks to obtain. Price spreads improved, but owing to higher
and a modest increase in copper prices. processing costs, and high exports, domestic markets
remained difficult. Scrap shortages were driving
Between 1998 and 2003, U.S. secondary copper-base prices. China, South Korea and India continued to be
scrap collection and processing capacity had been large importers of U.S. and European scrap.

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Refined copper consumption in the United States In 2005, China’s economy expanded by 9.9% over
increased about 10.4% between 1994 and 2000 to that of 2004. To support its rapidly expanding
nearly 3 million tons. However, by 2003, U.S. refined economy, scrap imports by China reached a record
consumption decreased to around 2.3 million tons, peak of 5 million tons in 2007. China was the largest
and then recovered modestly to around 2.4 million importer of copper-base scrap in 2006, with an
tons in 2004. Copper consumption was down again to estimated 66% of world copper scrap imports of 7.5
nearly 2.1 million tons in 2006 and 2007. It is also million tons.
worth noting that in 2006, the United States imported
record amounts of refined copper, reaching nearly 1.1 In response to environmental concerns, China
million tons. This was a continuing sign of a growing implemented import controls for scrapped electronics
and higher U.S. import reliance (nearly 40% in 2006, and the lower grades of copper scrap in 2002. Even
compared with only 2% in 1993) for copper. so, China reduced its import duty on copper scrap in
2006 to promote the development of the metal
Over the period 1996-2006, world refined copper recycling industry and to help shortages in the
consumption increased by over 36% to more than nonferrous metals sector, in general. China has been
17.1 million tons by 2006, an average of accused by the European scrap processors of
approximately 3.6% per year. Despite higher assisting its domestic companies through tax
secondary exports and lower copper consumption, the subsidies, credit facilities and other protectionist
United States remained a leading consumer of copper benefits that cause harm to the European scrap metal
from copper-based scrap with 14% of the world’s total recycling industry.
in 2007. In 2007, the United States consumed about
3.1 million tons of copper from all scrap and primary Trade restraints on scrap, such as import quotas,
sources, including about 920,000 tons from refined export licenses, price controls and other mechanisms
and direct melt scrap. have been used many times over the past 30 to 40
years in the United States and other countries. These
While copper recovered from new, manufacturing have been applied mainly during times of national
scrap sources has been increasing in the United emergency and supply shortage. The entire U.S.
States, copper recovered and consumed by industry secondary copper processing industry was treated as
from old, used product scrap sources has been a critical and strategic industry during these tight
decreasing. Copper recovered, and consumed by the supply periods. However, the United States has had
U.S. industry from old scrap was as high as 613,000 no trade restrictions on copper-base scrap since
tons in 1980, but was only 147,000 tons in 2007, 1970. All of the remaining copper in the National
despite gains in overall copper consumption over the Defense Stockpile was sold in 1993. In April 7, 2004,
period. However, if net scrap exports (632,000 tons in the U.S. copper consuming industries filed a short
2007) are classified as old scrap and are included in supply petition under the Export Administration Act,
an estimate for all old scrap recovered, the potential requesting imposition of monitors and controls on the
amount of copper in old scrap collected in 2007 was export of copper-based scrap. The U.S. Government
about 779,000 tons. This much higher value implies turned down the petition later in the year.
that the rate of old scrap copper recovered from the
end-use reservoir has not really diminished, as The U.S. secondary copper processing industry
otherwise might be indicated by reported U.S. scrap currently consists of 5 fire-refiners, 25 ingot makers,
consumption data. 30 primary brass mills, 14 wire-rod mills and about
500 foundries, chemical plants and other
World trade (imports) in copper-base scrap increased manufacturers. Wire rod mills do not consume much
by about 340% between 1989 and 2006, largely in scrap directly. Most of the chemical plants are
response to the increased industrial growth in the Far hydrometallurgical plants that have created
East and Europe. Asia and Middle Eastern countries businesses based on using secondary by-products
received about 76% of world copper scrap imports in produced by other metal production and metal
2005 and 2006. The United States continued to be the finishing. Many copper chemicals, such as cupric
largest exporter of copper scrap in the world, oxide, copper sulfate and others are produced from
exporting 17% of the world’s total copper-base scrap scrap in the United States. Some chemicals are also
exports in 2006. Exports of scrap from the United produced from the fluid streams of primary copper
States were over 800,000 tons per year for both 2006 refiners. While one chemical plant closed in Texas
and 2007. China used an estimated 30% of world during 2005, another opened in Arizona, associated
copper recovered from scrap in 2007, and has with a primary producer. Two ingot makers have
become the largest copper scrap-consuming nation in closed since 2003.
the world.

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The EU-15 as a group of countries is the largest ingot- Though most firms prefer to ship high-grade slags and
producing entity in the world. However, the United skimmings (up to 65% copper) to other domestic or
States (28%), followed by Italy, Japan, and Germany, foreign firms for further processing, about 28% of the
is the world’s leading ingot-making country, providing slag and skimming by-products produced are
the domestic foundry and brass mill industries with processed in the plant of origin. In addition, pickling
special alloys for casting and milling. Ingot-making, in solutions may also be reprocessed in house to
particular, is a very scrap intensive industry, using produce copper cathode. A significant proportion of
mostly scrap as its raw material. Even so, the brass these higher-grade products is exported to Canada or
mill industry (78% of 2006 copper-base scrap Mexico as a result of decreased U.S. processing
consumption) consumes most of the copper-base capacity.
scrap recycled in the United States. Some copper
tube and wire rod mills have had secondary smelters In addition to the copper-bearing ashes and residues,
or refineries associated with them because of their the copper-base secondary industry also produces
requirement for high-purity copper. Unfortunately, significant quantities of zinc oxide as a by-product of
most of these secondary smelting and refining its metal processing. The USGS estimates that about
facilities have closed, owing to the recent poor 30% of the world’s zinc is produced from secondary
economic environment for processing scrap and the materials, some of which is from the flue dust
easy availability of low-priced primary refined copper. collected during copper alloy processing. While some
of the production is suitable for direct use as animal
In 2006, recycled copper consumed in the United feed and agricultural products, most is sent to zinc
States was derived 87% from purchased new copper- smelters and processors for treatment and zinc
base scrap generated in the process of manufacture recovery. Only the poorest grades are landfilled.
and 13% from old scrap derived from used products.
According to the U.S. Geological Survey, purchased Spent furnace linings used in pyrometallurgical copper
new copper-base scrap yielded about 899,972 tons of and copper alloy processing are also by-products that
contained copper in 2006, 80% of which was sometimes have further value. The type of lining used
consumed at primary brass, tube and wire rod mills. A varies from chrome-magnesite brick to various types
manufacturer may generate up to 60% scrap in the of ceramic-like materials that are applied like cement.
form of slippings, trimmings, stampings, borings and While some spent linings are recycled for their metal
turnings during the manufacture of finished articles. content or used for concrete and other construction
This new, or mill-return, scrap is readily used by the material, some end up in the landfill. Spent furnace
industry in making new semifabricated products. A brick containing appreciable cadmium or lead are
secondary material becomes “purchased” scrap when shipped as hazardous material. All products sent to
it is traded or otherwise sent to market. Home scrap, landfill must pass the USEPA hazardous material test,
or runaround scrap, is used in-house, not marketed the Toxicity Characteristic Leaching Procedure
and not counted in consumption statistics. (TCLP).

In addition to the better known classes of purchased The TCLP has been challenged in court in recent
scrap, there is a smaller group of lower-grade, copper- years for its inherent difficulties in predicting all
base scrap known generally as low-grade ashes and disposal situations. The TCLP was not intended to be
residues, or as secondary by-products. By current representative of in situ field conditions, but rather of a
definition, these materials are comprised of copper- generic municipal solid waste (MSW) landfill worst-
bearing ashes, residues, drosses, skimmings, dusts, case scenario. In February 1999, the Science
slags and other materials containing less than 65% Advisory Board’s Environmental Engineering
copper, and are derived as by-products of other Committee (EEC) called for the need to review and
copper-base metal processing. According to the U.S. improve EPA’s current leachability testing procedure.
Geological Survey, which has long tracked the The U.S. mining industry and others have also
purchased scrap market for this material, only 34,839 challenged the applicability of the TCLP based on the
tons of low-grade ashes and residues was purchased physical and chemical differences between municipal
and consumed domestically for its metal content in waste sites and those used for large volume mine
2006. This is down considerably from the 300,000 wastes, among other uses.
tons to 500,000 tons that was marketed in the 1970s.
The downturn in domestic consumption of this Many problems have been derived from the
material coincides with cutbacks in the domestic application of CERCLA (the Superfund Law), passed
smelter industry, the decrease in use of reverberatory in 1980, and RCRA (Resource Conservation and
furnaces by the copper industry, and the closure of Recovery Act), passed in 1976. Most problems stem
secondary smelters and ingot makers. from the reporting, permitting, and other paperwork
requirements, as well as from the legal liabilities
stemming from application of these laws. For

3
example, liability concerns have been enormous products and, in particular, the development of
barriers to brownfield cleanup technologies. A brownfield sites. Nevertheless, the current economic
brownfield is a site, or portion thereof, that has actual situation continues to look more difficult for some
or perceived contamination and an active potential for parts of the secondary copper industry. This segment
redevelopment or reuse. Because financial institutions of the economy seems to be laboring under significant
can be liable for cleanup costs when they acquire the stress, caused in part by changing and more stringent
properties through default, they are unwilling to government regulations.
provide loans for development. Problems also
emanate from the potential responsible party (PRP) Problems on the horizon include the safe collection
aspects of CERCLA. The potential here is to be and processing of junked electronics equipment and
named liable for expensive cleanup solely because the potential for renewed recycling of radioactive
you may have done business with a firm named as a metal from dismantled U.S. nuclear plants. U.S. scrap
Superfund site. This approach to Superfund financing handlers and processors have been adapting rapidly
has caused businesses to think twice about shipping to handle the increased recycling of electronics scrap.
materials to certain firms. At the same time, however, adequate provision for
facilities to handle the relatively small amount of
In addition, restrictions on shipping products are radioactive copper scrap expected from dismantled
increasing. Once a product is classified as hazardous nuclear facilities remains a problem to be solved in the
and/or is controlled as to market, handling and future.
shipping, costs rise. Higher costs have resulted from
rulings that dictate how much can be stored in one How much copper has been recovered for reuse in
place or another, what must be classified as the United States over time? Recent calculations
hazardous, who may receive the material, and what indicate that since 1864, more than 66% of all primary
procedures must be followed through the entire copper consumed in the United States has been
production and marketing process. The permitting returned and reused as scrap. Based on reported U.S.
procedures and handling restrictions have not only data, cumulative primary refined copper consumed in
added to the costs of shipping, but have also reduced the United States since 1864 amounted to 126 million
the potential for by-product sale to other processors. tons by 2007. From this source, a cumulative
Further tightening of regulations through 43 million tons ( 34%) of copper from old end-use
reclassification of secondary products currently traded scrap has been returned for consumption by the
will result in higher costs and more products sent industry through 2007. This leaves an estimated 66%
directly to the landfill. remaining in use or recirculating as new
manufacturing scrap. The latter percentage includes a
Those firms that can have opted to invest money in very small amount known to have been dissipated
becoming more internalized with increased in-house through use as copper chemicals. It is not known how
treatment of products. Many have adopted unique much may have been irretrievably dispensed with or
cost-saving devices and policies. Some also are thrown away, but it is suspected that this is small and
instituting formalized, self-policing management may be only about 5% and no more than 15% of the
systems to improve their processes and products, via total measured consumption.
the ISO 9000 and ISO 14000 standards. Some parts
of the government are also taking a harder look at the
regulations that affect the smooth marketing of

4
CHAPTER 1: Industry Perspectives lows. At the end of 2005, world inventories, according
to the ICSG were only 851,000 tons and about 35%
less than that required for one month’s world
consumption. Despite efforts by the major copper
producers to bring mines back on stream during 2005
Global Industry Perspective and to increase production, shortages persisted
through much of 2006. By year-end 2005 and 2006,
World Copper Consumption and Production. copper prices exhibited marked increases, contrary to
Copper ranks third in the world consumption of many analyst’s predictions. Labor strikes, lower ore
metals, after iron and aluminum. According to the grades and other production problems seemed to
International Copper Study Group (ICSG), refined plague the industry. Production and consumption
copper consumption was 17.1 million tons in 2006, up appeared to be more in balance by year-end 2006.
from 16.7 million tons achieved in 2005. Estimates Even so, inventories decreased slightly through mid-
based on 9 months data for 2007 indicated that 2007, rising only modestly by year-end. Except for the
copper usage continued at a much higher rate, first 3 months of the year, prices remained mostly
reaching 18.2 million tons by year-end 2007. above $3 per pound throughout 2007, averaging
According to early data by the ICSG, copper usage about $3.23 for the year. December also saw brief
had increased by 7.1% for the first 9 months of 2007. dips below $3 per pound. World copper prices steadily
The major refined copper consuming nations of the decreased from 1995 through 2002 as a result of the
world in 2006, were China with 3.6 million tons (22%), more than adequate world supply of copper (see
United States 2.1 million tons (14%), Japan, 1.3 Table 1). During this period, copper prices reached
million tons (7%), Germany, 1.4 million tons (7%) and low levels not seen since the recession years of the
South Korea, 812,000 tons (5%). China did not show early 1980's. Since lower prices tend to prompt a
much consumption growth in 2006, compared with decrease in the supply of copper scrap, the use of
2005 in its official statistics. However, by September copper scrap as a component of world refined copper
2007, Chinese copper consumption was already equal also decreased from 16% in 1996 to about 12% in
to the amount reported for all of 2006. Many 2002. Higher prices since that time have prompted the
observers suspected that industrial Chinese copper percentage recovery of refined from scrap to gradually
consumption in 2006 was largely fed by withdrawals increase. According to the ICSG, refined copper from
from the government official stockpile, for which no scrap had increased to about 15% of total refined
figures were available to the public. copper production in 2006 and 2007.

China’s refined production was 3 million tons in 2006, A reasonable spread in price must be present
up about 15% from 2.6 million tons of copper between the current refined copper price and that for
produced in 2005. With this record production in 2006, purchased scrap in order for processing to be
China assumed position of leading refined copper profitable. The price spreads between No. 2 scrap and
producer, exceeding that of Chile. However, about refined copper are lower or higher in coincidence to
33% of China’s refined production is from scrap, the decreasing or increasing refined copper price in
whereas all of Chile’s refined production is from recent years, as shown in Figure 1. For example, the
primary sources. In addition to scrap imports, China price spread in the United States was as high as 32
has also become a leading importer of copper cents in 1995, but reached less than one-half that
concentrates, which are both processed domestically. amount during 2001 and 2003. The price spread for
these years was lower than the 17-18 cent spread
In this report, production and trade estimates were experienced during the recession years of 1982-1984.
made for 2007 on the data tables for the convenience The price spreads increased again between 2004 to
of the interested reader. These current year 2007 in tandem with the higher copper price.
estimates, for the most part, were based on 8 to 10
months of reported data. With increasingly stringent environmental regulations
and requirements, the costs to process scrap at all
The combination of soft demand and higher new levels, from low-grade scrap to pure metal scrap have
copper production resulted in a build up of significant escalated. The drastic cost squeeze during the poor
copper inventories from 1998 through 2003. However, pricing period prompted U.S. secondary processors to
the effort by the world’s major producers to trim back rethink business methods and in fact, some opted to
copper mine production between 2002 and 2003, get out of the business. It is encouraging to note that
resulted in a significant reduction of this surplus stock the estimated average price spreads were 26.6 cents
accrual by year-end 2003. By late 2004, inventories in 2004 , more than 37 cents in 2005, 57 cents in
on the LME , Comex and SHME reached all time 2006, and as high as 60 cents in 2007.

5
 Figure 1. Price Spreads Between Refiners No.2 Scrap
and U.S. Producers Refined Prices, 1974-2007
ZIP Reader.lnk

350 70

300
 60

250  50

Price Difference, cents

Price, cents per lb.

200 40


150 30
 
  
   
 
100 20
     

   
  
 
50
   10

0 0
74 976 978 980 982 984 986 988 990 992 994 996 998 000 002 004 006
19 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2
Years
Price Differences Refined Copper Buy #2 Scrap

Source: AMM and Metals Week

The refined copper price series used in Figure 1 is direct melt scrap may be underestimated, since these
the US Producers price, which always includes an data (with a only a few exceptions) are based largely
extra 4 cents to 5 cents per pound for shipping and on known (and estimated) semifabricate production in
insurance. This is the delivered price. If the COMEX a particular country. No amount of scrap that might be
price is used for the comparisons, the spreads would properly classified as “home scrap”, or that is lost in
be more narrow. Thus the 26.6 cent per pound the production process, is added to the direct melt
average spread for 2004 could also be interpreted as scrap presumed to comprise part of the end product.
21 cents per pound based on the average COMEX The general formula is comprised of total
refined copper price for the year. Refer to the scrap semifabricate production less amount of refined
and refined prices shown in Table 1 for a complete copper consumed. The copper content of direct melt
series and comparisons. Some reports indicated the scrap is based on percentages ranging between 80%
spreads for 2005 were narrow early in the year for and 90% of the total, dependent upon type of products
some grades of scrap. This was interpreted to be a produced (i.e., brass mill or copper rod mill etc). The
reflection of lower LME and COMEX prices and United States reports actual numbers for types of
aggressive offshore buying of scrap. A similar scrap consumed, but is unusual among nations
situation occurred late in 2007. In October 2007, reporting scrap data. The U.S. Geological Survey is
spreads were about 55 to 60 cents under the currently the scrap data collection and reporting
December No. 2 scrap contract. However, spreads for agency for the U.S. Government. Prior to 1995, this
No. 2 scrap for export in November 2007 were was done by the U.S. Bureau of Mines for over 100
reported to be around 34 cents under March 2008 years.
contract (ISRII Friday report, Nov. 30, 2007). During
the year, variability in scrap prices were generally Copper recovered from all scrap, as a percent of total
credited to Chinese buying and low U.S. scrap world copper produced, has ranged between the low
generation, and not to increased domestic demand. of 28% in 2003 to as high as 40% during 1995, as
shown on Table 2A and in Figure 2. The current rate
World copper recovered from all forms of scrap in of recovery (2006 and 2007) is estimated to be around
2006 (refined and direct melt, Table 2D) was about 32%. The percentage of scrap used by the world,
7.2 million tons, up from 6.2 million tons in 2004. In a relative to primary copper, noticeably plummeted after
word of caution, the actual amount of copper from 1996. This trend shows a striking parallel to the

6
 1/
Figure 2: World Copper Recovery from All Sources
And Percent Copper from Scrap, 1970-2007
Percent Scrap Million Metric Tons
20

18
50
16
45
14
40 PERCENTAGE SCRAP THE AMERICAS
12
35
10
30
8
25
ASIA 6
20
4
15
2
10 WESTERN EUROPE 0
5

70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 00 01 02 03 04 05 06 07
19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 20 20 20 20 20 20 20 20
Years

W. Europe Africa Asia The Americas Oceania % Scrap

1/ Includes copper in primary and secondary refined production and estimates for direct melt scrap consumption.
Data Sources: ICSG and USGS reports. See Table 2A, this report.

downward trend in prices over the same period (see year in 2006. Other major copper scrap consuming
Table 1). Periods of low scrap recovery, such as nations in the Middle East and Asian country group
those in 1975-1978, 1983-1984, and again in 2001- include Japan (9%), and South Korea (6%).
2003, coincide with low copper prices and surplus The Western European countries account for 30%
copper supplies. and (See Table 2D) and the countries of North and
South America accounted for 17% of world copper
Scrap consumption in Asia has followed a remarkable recovered from scrap in 2006. Germany, Italy, France
increase since the early 1980’s. As a group, the and the United Kingdom are the leading consumers of
Middle East and Asian countries account for about copper scrap in Western Europe. The United States
49% of world copper recovered from scrap in 2006 (14% of world total) is the major copper scrap
(see Table 2D). Consumption of copper from scrap in consuming country of the America group shown in
Asia grew from about 723,000 tons in 1980 to 2.4 Table 2D. The Americas (17%) are the third largest
million tons in 1995-1996. Following an industrial copper scrap-consuming region, after Western Europe
contraction in 1997-1998, the region experienced an and Asia. Other countries in Oceania and Africa are
8% drop to less than 2 million tons of copper in scrap. minor scrap consumers.
However, by 2006, Asia and the Middle East scrap
consumption had recovered to 3.5 million tons of World Trade in Copper Scrap. The United States
copper per year, largely through the continued (17% of world copper-base scrap exports in 2006) is
insatiable growth of Mainland China. China, with an the largest exporter of copper scrap in the world. U.S.
estimated 30% of world copper recovered from scrap exports of scrap have increased by 78% since 2000.
in 2006, has become the largest copper scrap-
consuming nation in the world. The Chinese Export duties have caused Russia’s export of copper
th
Government in its 11 Five-Year Plan (2006-2010) is scrap to slow to a trickle since 1999. Russia’s exports
encouraging the greater use of scrap metals to help of copper base scrap increased 3-fold between 1993
alleviate a shortfall in supplies. The target and 1998 to around 357,000 tons. but since 1999
consumption of secondary copper is 35% of the total have dropped sharply to about 2,000 tons per year
national copper consumption, an increase of about since 2003. Japan (10%), Germany (9.9%), United
14% (Peoples Daily Online, 2007). China has steadily Kingdom (6.6%), France (6%), Belgium (3.4%),
increased copper in scrap consumed from around Canada (3.5%), and Hong Kong (2.8%), are also
100,000 tons in 1980 to nearly 2.2 million tons per

7
 Figure 3: World Consumption of Copper from Direct Melt and
Refined Scrap, by Region, 1970-2007

7
Million Metric Tons, Copper Content

5 AMERICA
4

3 MID EAST & ASIA

2

1 EUROPE
0

70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 00 01 02 03 04 05 06 07
19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 20 20 20 20 20 20 20 20
Regions
Europe Mid-East & Asia America Oceania

Note: Europe includes Eastern Europe and Russia. America represents both North and South America countries.
Sources: International Copper Study Group and USGS. See Table 2D, this report.

major exporters of copper-base scrap, as shown in Taiwan, Hong Kong, Japan and India also have been
Table 3. In the past 6 years, exports of copper-based significant importers of copper base scrap. By early
scrap have increased significantly from Japan, from 2001, the availability of copper scrap was reported as
around 84,000 tons in 1999 to about 472,000 tons for especially tight in the United States, owing to the high
2006. exports to the Far East. Birch/cliff and berry/candy
grades were in particular demand. There are no
World imports of copper-base scrap, as shown in longer any secondary copper smelters in the United
Figure 4, increased by 340% between the years States and China has emerged as the major outlet for
1989-2006 in response to the significant industrial No. 2 scrap. Not much has changed since that time.
growth of the Far East and Europe. The Asia & Middle Supplies of scrap are still very tight in the United
East region is the largest recipient of U.S. and World States and in high demand for all U.S. consumers.
scrap exports, receiving some 76% of total world
imports in 2006, respectively. In 1989, Asia accounted In Europe, exports of copper scrap to the Far East
for only a 24% share, while Europe (61%), had a also increased dramatically at a time when local
higher share of the world's imports of scrap. In 2006, availability in the European Union (EU) was lower,
as shown in Figure 4, Europe (West and East creating problems for European refiners. Some in
Europe) accounted for only 21% of global scrap Europe, as well as in the United States, felt that unfair
imports. The countries in the Americas (North and customs regulations, as well as lower labor and
South America) have seen their share of world scrap environmental costs have enabled the Asian countries
imports diminish from 15% to around 3% over this to pay higher prices for scrap.
period.
Although the United States has increased its domestic
Of all countries, China has had the most significant processing of electronic scrap, U.S. export of low-
growth in scrap imports over the period 2000 through grade copper scrap derived from electronic products
2007, as shown in Table 4. Although Mainland China such as computers remains an issue of concern. Even
apparently suffered a marked collapse in amount of though China may be tightening its rules for importing
scrap imported in 1996 and 1997 owing to import electronics scrap, other poor countries may still be
restrictions, copper base scrap imports were again willing to accept these materials. According to some
higher by 1998. By 2001, China’s imports of copper- reports (Recycling Today, Feb. 2002), Pakistan has
based scrap was 4-times that of 1996. South Korea, become a bigger market for electronic scrap and used

8
 Figure 4. Trade in Copper and Copper Alloy Scrap
by World Region, 1989 and 2006

Asia & M.E. 76%

Asia & M.E. 24%
America 15%

America 3%

Europe 61%
Europe 21%
1989 Imports 2006 Imports
1.7 million tons 7.5 million tons

Asia & M.E. 25% America 26%

Asia & M.E. 17% America 28%

2% Row 3% Row

Europe 52%
Europe 46%

1989 Exports 2006 Exports

1.6 million tons 4.7 million tons

Source: International Copper Study Group

computers. China reportedly applied import unfairly. As a result, the U.S. Copper and Brass
restrictions on electronic scrap and in May 2002 Fabricators Council (CBFC), representing domestic
instituted a substantial tariff on class 7 scrap. This brass mills submitted a 301 petition concerning the
class includes lower grades of copper scrap such as trade of copper and zinc scrap to the U.S. Trade
unprocessed wire and die cast alloyed parts. The tariff Representative on Nov. 14, 1988. The application was
may have also been enacted to force the domestic not successful in developing U.S. controls. Domestic
smelting industry to use higher grades of scrap as a semifabricators asserted that European (EEC) and
pollution reduction measure. China continued to Brazilian brass mills had been able to maintain
tighten regulations and began in November 2004 to materials cost and product price advantages since the
ban all used television sets and other electronic scrap middle 1970’s, largely through export controls on the
imports in a bid to clean up its environment. flow of copper and zinc scrap. However, in 1992, the
EC terminated the export controls on copper and
To maintain adequate supply for the home market, the copper alloy scrap. Several Asian nations and Russia
Chinese Government has applied strict controls on the have maintained scrap market controls in recent
export of copper-based products. In November 2006, years. The Bureau of International Recycling (BIR), a
the export tax rebate on copper products was cut to European recycling organization, recently assisted
5% from 13% and the export tariff on copper Romanian companies in opposing a Romanian
concentrates increased to 10%. Meanwhile, export governmental decree to impose 20% to 30% export
tariffs on copper scrap, blister copper and electrolytic taxes on nonferrous and ferrous scrap.
(refined) copper were also raised The Chinese
Government levied an export tax on nonferrous scrap In April 7, 2004, the CBFC and Non-Ferrous Founders
at 10% from June 1, 2007 (Recycling Today, 5/23/07). Society filed a short supply petition under the Export
Administration Act, requesting imposition of monitors
Export controls on scrap (such as those imposed by and controls on the export of copper-based scrap.
Russia) have been commonly applied in many nations ISRI and its members were opposed to the petition as
in the world during periods of scarce supply. they did not want exports restricted. The Commerce
Historically, copper base scrap has been a highly Department issued its decision in August 2004 citing
prized raw material, especially in those nations with no need for controls or monitoring of copper-based
scarce natural raw material sources for copper. scrap exports. See Appendix A for a more complete
European scrap export controls during the 1980’s discussion.
were seen as affecting the U.S. copper industry

9
 Figure 5. U. S. Total Copper Consumption 1/
Including All Scrap, 1964 to 2007

Million Tons, Copper Percent Scrap in Consumption

5 60


50
4
 
 
    
  

   40
      
 
3
     
    
  30
   
2 
20

1
10

0 0

64 66 6 8 70 72 7 4 76 78 80 8 2 8 4 86 8 8 90 9 2 94 9 6 98 00 0 2 0 4 06
19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 20 20 20 20
Years

Copper Consumption Percent Scrap

Source: U.S. Bureau of Mines and U.S. Geol. Survey.

1/ Total Copper Consumption = Primary refined, secondary refined + copper in direct melt scrap.

The voluminous paperwork requirement the Chinese because Chinese importers could pay more for scrap,
government implemented for the importation of scrap but still make a profit. U.S. manufacturers that use
was viewed as an impediment in early 2004. Some scrap were faced with higher prices for raw materials,
scrap recyclers and brokers labored to comply with thus increasing their production costs. Finished
export regulations being put in place by the Chinese products from China were subsequently undersold in
Government’s Administration of Quality Supervision U.S. markets (US Info.State.Gov. 10/7/2003).
Inspection and Quarantine (ASQIQ) (Recycling
Today, August 2004). The significant load of Pegging the yuan to the dollar was also reported as a
paperwork required had an initial deadline set at July deliberate strategy to support Chinese industry and
1, 2004 in order to be registered or permitted to ship boost exports. China’s undervalued currency was
scrap to China. Not only was the information acting as an additional trade barrier to U.S. exports
requirement voluminous, but some information such and an unfair subsidy for all Chinese exports
as floor plans and other operational details of the (Congressional-Executive Commission on China, Sept
exporting company, required to qualify for the CCC 24, 2003).
mark system, were objectionable. The suspicion
existed that the Chinese importers were determined to In September 2007, China Logistics News (China
help themselves to efficient production facility know Economic Review) reported a huge back up of
how. containers filled with scrap, caused by a crackdown
on importers trying to avoid complying with the new
Another problem with copper scrap exports to China duties for scrap. Two months previously, Chinese
revolved around China’s handling of its VAT (Value- customs officers launched a major offensive against
added Tax). The VAT tax on copper waste and scrap importers, who had been trying to avoid complying
was 17% in 1999 (www.chinavista.com). The same with new duties. There had been a widespread
tax applied to refined copper imports. Chinese copper practice among many Chinese importers of mixing
scrap importers and Chinese customs officials were lower content scrap with higher purity material to
accused of manipulating the VAT to the detriment of avoid paying higher taxes. Duties are applied to the
U.S. industries. Chinese importers received a rebate copper content, so a reduced copper content means
on VAT and then further manipulated import lower duty. Another problem area is “mixed” loads of
documents to gain greater VAT refunds. These scrap where the high value copper is loaded in front of
actions caused global copper scrap prices to rise the container and lower grade scrap is loaded in back.

10
 Figure 6. Trends in U.S. Net Exports and Consumption
of Copper in Scrap 1/, 1980 - 2007
1600

1400  
   

1200
  
 
  
1000
      
 
  
800  
 
600 
 

  

400

  
  
200
   
      
0 
80 981 982 983 984 985 986 987 988 989 990 991 992 993 994 995 996 997 998 999 000 001 002 003 004 005 006 007
19 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2

Net Exports Ref. Scrap DM Scrap 

Total Scrap

Source: US Geological Survey .

1/ Revised to include copper from copper- base and other-base scrap.

Some observers have used problems in Chinese Ukraine’s parliament gave approval to a bill in late
trade regulations to explain the tremendous 2006 that would lift the ban on exports of scrap
differences between reported world statistics for nonferrous metals. An export duty of 30 Euros per
copper scrap imports and exports See Tables 3 and 4 metric ton would apply the first year the bill is in effect
in this report for differences. Among importing and would be gradually reduced to 15 Euros per
countries, the import statistics for China seem to be metric ton over the next 5 years. The duties would
the most suspect. Copper scrap imports are over start when Ukraine joined the World Trade
reported because some other industrial waste has Organization. (Recycling Today, 11/30/06).
been claimed at customs as copper or copper alloy
scrap. Some believe this may be the result of the World Production and Trade in Copper Alloy Ingot.
lower copper scrap import duty relative to other While copper and copper alloy ingot production and
industrial wastes. Some traders may be trying to avoid trade are not large in volume compared with other
the higher import duty by importing non-copper copper products; they form the foundation blocks for
industrial waste as copper scrap. Imports of scrapped important specialty metal fabrication industries. Many
electrical domestic and office goods also may have nonferrous foundries, brass mills, steel mills and other
been imported as copper scrap, since these have parts of the world's manufacturing industry are
been prohibited since Aug. 15, 2002. dependent on the special alloys produced by these
essential processing plants. Because the ingot
China reportedly reduced the import duty on copper makers and associated foundries of the world are
scrap in 2006 and 2007 to promote growth in the heavily reliant on scrap, especially old scrap from
metal recycling industry and assist the nonferrous returned manufactured and used products, it is
metal sector in its need for raw materials. China important to put this industry in world perspective.
reduced the import tariff for copper scrap from 1.5% to
0% in mid-July 2007 (ISRI Friday Report, July 20, The United States is a world leading producer of
2007). In late 2007, China announced that it will copper and copper alloy ingots and foundry products
remove import duties on refined copper. The current from scrap (see Tables 5A, B and C and Table 10).
3% import tax for refined copper will be cut on Jan. 1, The United States produced 254,000 tons (23%) of
2008 (12/28/07, (www.recycleinme.com). In mid- world nonferrous foundry products in 2002 and
November 2005, China also signed the first East 207,000 tons in 2006. Italy (7.4%), Japan (8%) and
Asian trade agreement with Chile as an important bi- Germany (7%) are also significant producers of
lateral trading partner. Chile is the largest copper nonferrous foundry products. China (30%) has
producer in the world.

11
increased foundry production significantly since 1999, and filters in the automotive and aerospace industries,
producing more than 400,000 tons per year by 2005. for electrical and electronic applications, for antifouling
paints and coatings, and for various chemical and
The same countries are significant copper-based alloy medical purposes. Copper chemicals, principally
ingot producers with the United States producing 28% copper sulfate and the cupric and cuprous oxides, are
of the world total alloy ingot production. More than half widely used as algaecides fungicides, wood
of the world’s alloy ingot production, of around preservatives, copper plating, pigments, electronic
440,000 tons per year in 2005, is exported. According applications and numerous special applications.
to the ICSG Copper Bulletin, world ingot imports were
256,000 tons and exports were 310,000 tons in 2006. U.S. Consumption of Copper. In the United States,
During 2006, China (18%), Germany (11%), Italy copper derived from both primary (mined) and
(5.6%), Taiwan (5.4%), Canada (4.9%), and France secondary (recycled) sources is consumed at
(4.3%) were the largest importers of ingot. Since industrial production plants. U.S. industry import
1999, China has increased its imports of ingots by a reliance for copper in the last 14 years has increased
factor of 6 to around 67,000 tons in 2004 and 62,000 from less than 1% of domestic consumption in 1991 to
in 2005. The United States also has almost doubled over 43%, and 38% in 2005 and 2006, respectively. In
its ingot imports in the past two years to around 2006, a record level of refined copper, around 1.1
10,000 tons. The United States (40,000 tons), Japan million tons, was imported into the United States. This
(33,000 tons), South Korea (20,000 tons), the United compares with only 543,000 tons of refined imports as
Kingdom (17,000 tons), Germany (21,000 tons) , recently as 1996. Copper derived from domestic
Hong Kong (11,000 tons) and Spain (9,600 tons) were mines and as well as from domestic scrap sources
the leading exporters of ingot in 2006. have steadily decreased in recent years as imports of
refined copper have increased.
Over the past 5 years, U.S. ingot exports were
between 19,000 tons and 40,000 tons, reaching a Recycled copper used to make semifabricated
peak in 2006. U.S. ingot imports decreased markedly products may be derived from (1)scrap that is first
from about 23,000 tons per year in 1999 to around refined before use (refined scrap), or (2) from copper
5,000 tons per year, but have increased significantly and copper alloy scrap that can be directly melted at
in 2006 and 2007. In examining the ingot import data the time of use (direct melt scrap). Total refined
of Table 5B, it can be seen that ingot imports have copper, from both primary and secondary sources,
decreased generally in every region of the world, with consumed by the U.S. industrial sector in 2006 was
exception of the Middle East and Asia, which has 2.1 million tons, according to the U.S. Geological
tripled the amount of alloy ingot imports since 1999. Survey (see Table 6), and still somewhat lower than
the high point of 3 million tons in 2000. Copper
consumption for 2007 was estimated to be about the
same, or slightly lower. Of the total refined copper
Domestic Industry Perspectives consumed in 2006 only 44,778 tons (or 2%) was
derived from scrap processed at a refinery (see Table
Domestic uses for Copper. About 75% of the copper 7). This is down considerably from 480,000 tons (25%
consumed in the United States is for electrical and of refined consumption) of copper from refined scrap
electronic uses, finding widespread application in in 1989. In addition, the United States industrial sector
most end use sectors of the economy. According to consumed about 909,000 tons of copper in 2006
the Copper Development Association (CDA), 7.78 derived from direct melt, copper-based scrap (See
million pounds (3.5 million metric tons) of copper and Table 2C). Total copper from scrap (refined plus
copper alloy mill products were shipped for domestic direct melt copper base scrap and from other than
2006 end-use markets, as follows (electrical is copper-base scrap) amounted to about 972,000 tons
distributed through all end-use markets): Building (Table 2D) in 2006. The range in annual average
Construction (50%), Electrical and Electronic Products copper content for direct melt copper-based scrap in
(19%) Industrial Machinery and Equipment (9%), the United States has been 83% to 85% of the gross
Transportation Equipment (11%) and Consumer and weight over the past 10 years, according to an
General Products (11%). In 2005, copper mill analysis of data provided by the U.S. Geological
production of 7.660 million pounds was marginally Survey.
higher than the low point of 2003, but still much below
the high point of 9,379 million pounds for 1999 Traditionally, scrap used in refining and smelting has
Although smaller in total tonnage than the electrical been made up mostly of “old” scrap, while the
and electronics uses of copper, the copper powder purchased direct melt scrap used by brass mills is
and chemical industries also provide important mostly “new”, customer-returned scrap. The rate of
products. Copper and copper alloy powders are used recovery for “old” scrap copper in the United States is
for brake linings and bands, bushings, instruments, related to the variability in the copper price, the

12
domestic industry demand for this type of raw copper from old scrap and refined from scrap, in
material, competition from exporters, and the particular, experienced a significant decline (See
availability of primary copper. The small amount of Tables 6 and 7). For example, copper from old scrap
U.S. secondary refined copper in 2006 was 66% recovery was as high as 613,000 tons in 1980, but
derived from old scrap sources and 34% from new was only about 141,000 tons in 2006. Exacerbating
scrap sources, according to the U.S. Geological the decline in collection and processing of old and
survey. The amount of secondary copper in U.S. low-grade scrap in the United States has been the
refinery production was only 44,778 tons out of a total closure of essential U.S. smelting and refining plant
1.25 million tons refined copper (Table 7). This was capacity. All U.S. copper scrap smelting plants, most
down considerably from around 480,000 tons of scrap refining plants and some ingot makers have
refined copper derived from scrap in 1989. The closed owing to the higher costs associated with tight
significant decrease observed since 2000 was the environmental regulations, increased worker safety
result of the gradual and complete closure of all of the standards, and the competitive pressures from
secondary smelters in the United States. Refer also to increased export of scrap.
Figure 8 for complete statistical details on smelter
capacity changes over this period. Scrap is a necessary raw material in the U.S.
manufacturing cycle. Not only does the U.S. industry
Ingotmaking also uses large quantities of copper from generate many tons of copper-base scrap, but it also
"old" scrap (67% derived from old scrap in 2006). needs and uses many thousands of tons each year
Copper from old scrap only made up 13% of total during the process of new manufacture. Customer-
copper recovered from copper-base scrap in 2006 returned new scrap tends to be recirculated to the
(USGS, 2006 Minerals Yearbook, table 7). Some plant of domestic origin. ). In 2006, about 98% of
copper tube mills may use a higher proportion of old copper-based scrap consumed at brass and wire rod
scrap when purchased from dealers as good clean, mills was new scrap, according to the U.S. Geological
No. 1 copper scrap. It is many times impossible for a Survey (2006 Minerals Yearbook, table 11).
mill to determine whether the scrap is “old” or “new” in There had been a gradual increase in total purchased
its origin after it has been chopped and processed by scrap marketed in the United States through 1997, as
an intermediary. shown in Table 6 and in Figure 6, which was
presumed to be the result of the steadily increasing
U.S. scrap statistics shown in Table 6, represent industrial base from which more customer return
consumption, or copper scrap usage, as reported at scrap is generated It was also the result of the gradual
industrial plants, and thus, do not reflect the total decrease in processing capacity for old scrap. Since
amount of material collected at scrap dealers and 1997, however, total scrap use has declined,
traders. An increasing amount of U.S. scrap collected coincidental to the significant increase in U.S. scrap
has been exported in recent years. Using an exports (see Table 3 and Table 8). An increase in
assumption that most internationally-traded copper primary copper supplies and lower copper prices over
scrap may be derived from used materials, the the period also contributed to decreased use of scrap
addition of U.S. scrap exports to old scrap reported as until 2003 (see Table 1).
consumed by the industry will provide an estimate of
total old scrap recovered in a particular year. This also Even while the brass and wire mill sectors of the U.S.
assumes, of course, that most new scrap is returned secondary-based industry were expanding capacity,
to the domestic mill of material origin and is not also mill consumption of scrap copper relative to primary
sold abroad. copper was decreasing. Until 1982, copper from all
scrap sources had grown each year in the United
Old scrap recycling and its contribution to U.S. total States, as a percent of total copper consumed,
copper derived from all scrap has fallen from 43% in varying between 7% (in 1906) to 50% (in 1950).
1993 to 15% in 2007. U.S. recovery and consumption However, from a peak of around 49% in the early
of “old” scrap was highest during WWII, the 1950’s 1980’s, the contribution of copper from scrap has
and 1960’s, which were years of high copper demand gradually been decreasing to around 31% in 2006
and high prices. Old scrap recovery was also high (see Table 6). Copper prices have escalated since
during the Great Depression years, when mine 2003, but a commensurate increase in scrap
production was severely curtailed. As a percent of consumption by the U.S. industry has not been
total copper consumed, (see Figure 5 and Table 6) evident. Export of U.S. scrap supplies have remained
copper from scrap has declined from 49% since the at all time highs throughout this period.
early 1980’s to around 32% in 2006. Despite the
robust U.S economy of the 1990's, domestic use of

13
 Figure 7: U.S. Copper Alloy Ingot Production
By Ingot Group, 1984-2006
Thousand Metric Tons, Gross Weight
250

200

150

100

50

0
1984 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006

Tin bronzes Leaded red/semired High-Pb Tin Bronzes Yellow brass Mn & Al Bronzes
Hardners, Misc. Nickel Silver Silicon bronze/brass

Source: U.S. Bureau of Mines and Geological Survey Mineral Yearbooks

Copper consumption from scrap, as shown on Table around 1.1 million tons in 2007. U.S. net exports of
6, does not include the significant amount of run-a- scrap in 2007 were estimated to be 800,000 tons, up
round or home scrap that is generated at every plant. from a net export of around 63,000 tons in 1993, and
Between 15% to 40% of raw material consumed 140,000 in 1997.
remains in the production cycle of brass and wire mills
and is recycled again and again. To include this The United States is a significant exporter of copper
material in consumption statistics each year, however, and copper alloy scrap as shown on Tables 3 and 8,
would be to double count the material each time it and has been the world’s largest exporter of copper-
passed through the production process and was based scrap since 1999. The most significant U.S.
scrapped. Yet, this material is available and is very scrap export destinations are in Western Europe and
necessary for the complete production cycle. Asia. Although the amounts have been declining since
Unfortunately, few statistics are available to quantify 1997, the United States also imports around 100,000
run-a-round material. tons per year of scrap. The most important U.S.
import sources of copper and copper alloy scrap in
U.S. Trade in copper and copper alloy scrap. 2006 were Canada (44%) and Mexico (31%) (USGS
Copper and copper alloy scrap of all types has Minerals Industry Surveys, Feb. 2007, Table 16).
significant intrinsic value for the manufacturing Scrap exports generally have been increasing since
industries of both the United States and the World. the early 1970’s, reaching peaks in 1989, 1995 and
Secondary copper base scrap, including lower-graded again in 2006. There are strong indications that
copper materials with by-product metal value, are all exports may set another record in 2007 (an estimated
commodity-like materials that are traded (bought and 892,000 tons). U.S. scrap imports and exports were
sold) and used just like other raw materials. As a down in 1996 through 1999, as a result of the
consequence, recycled materials form a significant worldwide depressed prices for copper, the strong
part of the U.S. copper exports and imports. This has U.S. dollar and a temporary setback in Chinese
been particularly significant in recent years since the imports during the early part of this period. The lower
manufacturing bases of the Asian countries have scrap price and stronger dollar also combined to make
been growing and demanding more raw materials. U.S. scrap scarce for domestic buyers as well as
The domestic market for scrap is still larger than expensive for foreign buyers for a short period of time.
exports though exports have been growing at a faster In recent years, however, foreign buyers (principally
rate. U.S. industry consumption of scrap has China) have managed to outstrip local mills in
decreased from around 1.77 million tons in 1997 to

14
competition for scarce purchased scrap. Figure 8. Trends in U.S. Copper Smelter
Exports have escalated since 2000.
and Refinery Capacities
In lieu of scrap, primary copper at bargain (Thousand Metric Tons, Copper)
prices between 1998 and 2003 provided a 1982 1989 1994 2004
ready substitute in the United States for
Secondary 315 481 511 0
those who could utilize it. However, owing Smelters
to the types of furnaces used, size of
charge needed, and chemical Secondary
Refineries 545 315 311 171
requirements for certain alloys, this was
not possible for all secondary metal users, Reverb.
and the market became difficult for these Smelters 1526 474 210 0
industries. Those mills that were Primary
dependent upon direct melt alloy scrap Flash 173 868 1315 900
Smelters
were highly affected by the increased U.S.
exports.

The trend in U.S. net scrap exports Because many of these materials are associated with
appears as a mirror image to the trend of copper the brass and bronze making process, trade in zinc
recovered from refined scrap, as shown in Figure 6. dross, skimmings, ashes and residues are also shown
When refining from scrap (largely “old” scrap) is high, in Table 9. As measured in zinc content of zinc ash
net exports (exports less imports) are lower. Lower and residues (HTS 26201960), exports reached a
exports and higher imports of scrap in the early 1980’s peak in 1992 but declined through 1999 to 4,500 tons
were in part owing to the stronger dollar of the period. Exports of zinc ash and residues increased
significantly since that time to reach 25,000 tons in
Trade in low-grade, copper-containing ash and 2002, and 13,200 tons in 2004, but were down again
residues has been recorded by the Bureau of the to 4,220 tons in 2006. Zinc ash and residues imports
Census under HTS 262030 since 1989, when the steadily increased to around 24,300 tons, as
harmonized code was instituted in the United States. measured in contained zinc through 1998, but then
Prior to this nomenclature, the TSUS standards and decreased to a range of between 14,000 and 17,000
nomenclatures were used. For exports, the TSUS tons until 2005. Zinc ash and dross imports were
number is 6030010 and for imports, it is TSUS again higher at 33,750 tons in 2006.
6035040. Exports of "ashes and residues containing
mainly copper" are reported in gross weight of U.S. Export Controls on Scrap. During periods of
material. The import data are in copper content, but it high military activity and/or difficult economic
can be extrapolated to gross weight for comparison conditions, copper and copper-base scrap has been in
with the USGS reports for consumption of low-copper such tight demand and scarce supply that U. S. export
ashes and residues. Although the material may controls and other restrictions have been placed on its
contain up to 65% copper, an average copper content use. Tight supply periods occurred in the 1960's and
of 35% was used in estimating the gross weight for early 1970's, occasioned not only by requirements of
exports and imports on Table 9. the Vietnam War, but also by the effects of extended
labor strikes during the late 1960’s. To compensate
The major trading partners receiving ashes, residues for the severe shortages, more than 1 million tons of
and slag from the United States for further processing copper from the National Defense Stockpile were
are Belgium, Canada, Germany, Mexico, the United released. In addition, during the early 1970’s, price
Kingdom and, more recently, China. Major import controls were implemented. A brief review of the
sources are the copper producers of Botswana, Chile, historical events surrounding the use of export and
Mexico, Canada and Australia. Copper ashes and price controls relative to the copper market and the
residues exports increased from the early 1980's to need for copper scrap is instructive. The reader may
reach 28,110 tons in 1995, decreased to as low as refer to Appendix A for a more detailed accounting of
2,950 tons in 2002 and increased again to 20,000 events prompting the need for export controls. Given
tons in 2004 and 2005. Copper ash and residue the propensity for military efforts to use large amounts
exports were 51,000 tons in 2006. Although imports of copper and its alloys, as well as to cut off major
had been decreasing (from 5,400 tons of copper sources for copper around the world at times, it is
content in 1988 to less than 700 tons in 2002 (see highly possible that export controls and the pressure
Table 9.), imports of ashes and residues were higher for increased use of secondary copper can occur
between 2003 to 2006. again. All of the remaining copper in the National
Defense Stockpile was sold in 1993.

15
Products and by-products from Scrap 40,000 tons in2006. Imports of ingots had dropped off
sharply from 23, 400 tons since 1999 (see Tables 5B
Wrought copper and copper alloys. The making of and 5C) to between 4,000-6,000 tons per year until
brass and bronze wrought metal alloys by brass mills 2006. Ingot imports increased by 75% in 2006 to
accounts for the largest share of copper recovery from around 10,000 tons. Ingot making was a critical U.S.
scrap. Wrought copper and copper alloys are industry during World War II, comprising a basic part
produced from purchased scrap, home scrap, refined of the essential brass mill and foundry support for the
copper, and other metal alloying additives. These war effort. This was so much the case, the Defense
alloys are fabricated into products such as sheets, Production Act required that, among all other
tubes, rods and pipes. Wire rod mills produce Government copper surveys, only the ingotmaker,
continuous cast, pure copper rod for making wire that foundry and brass mill data surveys were mandatory
is drawn down to various types of coated and under penalty of law. Special alloys and the special
uncoated wire. castings, fittings and parts made for military uses are
dependent upon domestic production from
Because of the stringent requirements for making ingotmakers and foundries.
copper wire, wire rod mills use mostly refined copper
in making rod. The small amount of scrap that is used Ingot makers produce a wide range of cast copper
by wire rod mills must first be refined. Only one wire alloys for the nonferrous foundries. Ingots weigh about
rod mill in the United States has a continuous system 30 pounds each when cast, being of a small enough
for fire refining, melting and rod casting from scrap. size to suit foundry furnaces. Production trends for
This mill uses the company's own customer-returned several broad ingot groups are shown on Table 10 .
scrap from its wholly-owned wire mills in the fire- The most important of these are the red brass,
refining plant. For 2006, the combined semifabricate bronze, and yellow brass groups. Figure 7 clearly
production of brass and wire mills amounted to 3 shows the gradual decline in U.S. ingot production
million tons of copper and copper alloy products. since the middle 1980's with another sharp drop since
(Table 10). This was somewhat lower compared with 2000. The leaded and semi-leaded red brass and the
3.2 million tons of semifabricated products produced tin bronze categories of ingot seem to show the most
in 2005 (Table 10), and considerably lower than the volume decrease since the late 1980’s. A decrease in
peak of 3.9 million tons reached in 1999-2000. The hardeners and master alloys seems to have occurred
decrease in 2006 is a continuation of the U.S. since 2000. The general range in ingot compositions
industrial retraction that has been experienced since are shown on Table 11. There are actually hundreds
2000. of ingot metal compositions designed for special
tasks. The groups shown in Table 10 are very
U.S. copper consumption statistics, as shown in Table general.
6, are reported from brass and wire mill activity. These
statistics do not represent the entire U.S. community’s Individual grades of copper and copper alloys have
consumption of copper, the statistics for which would been designated in the past by a three-digit number
include copper contained in finished imported goods, series developed by the industry. More recently,
such as cars, refrigerators and other copper- however, this series has been incorporated into the
containing goods. Imported semifabricates used at Unified Numbering System (UNS) for metals and
finishing plants are also not included. To determine a materials developed by the American Society for
complete U.S. societal copper consumption estimate, Testing and Materials (ASTM) and the Society of
copper in imported finished goods also should be Automotive Engineers (SAE). This system designates
considered. This is difficult to estimate, and such an each alloy by 5 digits preceded by the letter C. The
exercise is beyond the scope of this paper. Judging by UNS system is administered by the Copper
the volumes of products scrapped, however, it is Development Association Inc.(CDA). There are about
suspected that the U.S. society remains the largest 370 types of copper and copper alloys divided into the
consumer of copper in the world, regardless of where broad categories of wrought and cast metals. Within
it originated or how it was used. these two categories, the metals are further
subdivided into classes as follows:
Brass and Bronze Ingots. According to the U. S.
Geological Survey, ingot production (including master Coppers: Metals containing at least 99.3% copper.
alloys) in the United States was about 128,000 tons There are 44 numbered coppers, including oxygen-
(see Table 10) in both 2005 and 2006. Ingot free, tough-pitch, and deoxidized varieties.
production has been less than 200,000 tons in the
United States over the past 10 years. This is down High-copper alloys: Copper content of cast alloys is
considerably from 300,000 tons to 380,000 tons at least 94%; copper content of wrought alloys is 96%
produced in the 1960’s and 1970’s. U.S. ingot exports to 99.3%. This class includes the cadmium, beryllium,
have increased significantly in recent years to around and chromium copper alloys.

16
Brasses: Copper alloys containing zinc as the copper since 1987, from 27% to 3% in 2007 can be
principal alloying element. There are 3 families of observed on Table 7.
wrought brasses and 5 families of cast brasses.
SeBiLOY 1 and II, were recently introduced as lead- Copper Anodes for Plating. Copper anodes are
free alternatives to the leaded-red brasses used in produced by ingot makers and foundries in several
plumbing. These lead-free cast red brasses contain shapes designed for ease use in plating. Copper
bismuth and selenium as principal additives. anodes that contain phosphorus are designed for use
in copper sulfate plating systems. Pure copper anodes
Bronzes: Copper alloys in which the principal alloying are used in copper cyanide and other alkaline plating
element is usually tin, and which contain other metals systems. Important in selecting the correct anode for
such as aluminum, lead, phosphorous, and silicon, but plating are the following characteristics: Anode area
not zinc or nickel. and copper concentration; the size and shape (balls,
nuggets, bars), the potential for bridging (caused by
Copper Nickels: Copper alloys with nickel as the small baskets and large nuggets), sludge build-up, the
principal alloying metal. grain structure of the anode, the phosphorus content
and lastly, the preparation of the anode (cleaning).
Copper-nickel-zinc-alloys: Copper alloys containing
nickel and zinc, as the principal and secondary Black copper. Black copper is an intermediate
elements; commonly known as nickel silver. product produced in a blast furnace from low grade
scrap. Black copper still contains some iron and zinc
Leaded coppers: Cast copper alloys containing 20% along with most of the tin, lead, and nickel of the
or more lead, usually a small amount of silver, but no charge. A typical composition is 75% to 88% copper,
zinc or tin. 1.5% tin, 1.5% lead, 0.1% to 1.7% antimony, 3% to
7% iron, and 4 to 7% zinc. Traditionally, this material
Special alloys: Copper alloys with compositions not can be refined in a scrap converter with the addition of
covered by the above descriptions liberal coke to the charge, which adds extra heat and
provides a mildly reducing condition, thus facilitating
Master alloys and hardeners are also produced by a the removal of zinc, tin, and lead. Copper anode is
select group of ingotmakers for use by others in then poured for further refining in an electrolytic tank
performing certain functions in their melt. Master house. Slag, produced as a by-product may contain
alloys usually contain 10-15% of the desired metal 1.5% copper, or more, and can be granulated and
and the remainder is copper. They perform the sold as aggregate, or reprocessed when the copper
function of making the addition of potentially difficult content is high enough.
metals easier to a melt. Master alloys are produced as
shot or ingot form and are used as a melt addition to Copper Chemicals and Powders. Most copper
deoxidize, harden, improve fluidity or control chemicals made in the United States today, such as
composition in many base alloys. For example, the copper oxides and hydroxides and copper sulfate,
phosphor copper master alloy is used as a deoxidizing are derived from processing copper scrap, copper
additive in making copper tube. sludges, or from the process waste liquors associated
with refining copper, copper etchants, brass pickle
Refined Copper. According to data collected by the solutions, and other metal processing. Generally, the
U.S. Geological Survey, 44,778 tons of refined copper purer, less contaminated forms of scrap are preferred
was produced from scrap in 2006 down significantly for making chemicals to avoid inclusion of deleterious
from 460,000 tons produced in 1993. Refined metals. Even so, some hydrometallurgical processes
products formed include cathode, ingots, billets, shot permit the use of some types of mixed scrap, such as
(small metallic pellets), wirebar and continuous cast copper-plated steel, and printed circuit boards.
rod. In addition, only about 746 tons of copper powder Copper powders are also made from refined metal
was also produced from scrap in 2006. Table 12 derived from scrap. Copper powder and copper
shows the manner in which copper is extracted from sulfate production in the United States is shown on
scrap and the form of recovery from 1995 through Table 10. According to the U.S. Geological Survey,
2006. Owing to the few plants actually fire-refining, copper sulfate production was down to 19,500 tons in
this data is currently withheld by the reporting agency 2006. This continues the significant decline in
(U.S. Geological Survey), but included in the total production that is down from 33,200 tons in 1989, and
refined number. The historical production of refined from about 55,000 tons produced in both 2000 and
secondary copper in the United States for the years 2001. A copper sulfate production facility closed
1968 through 2007 is shown on Table 7. Refined during the 2004.
production for 2007 is estimated based on 9 months
reported data. The decreased recovery of secondary

17
18
Copper powder production from scrap has ranged Among other uses, slags have been used for the
between 8 tons to 11.7 thousand tons in recent years, production of light-weight aggregate and rock wool.
but reportedly was less than 200 tons in 2006,
according to USGS reported data. Even so, total In making some master alloys, special types of
copper powder exports (HTS 740610-20) have residues are generated. In the case of making
increased steadily to around 11,465 tons in 2006 phosphor copper master alloy, the dominant residue
(U.S. Domestic Exports, datawebb. usitc.gov) . Only contains phosphoric acid. Most of the phosphoric acid
3,720 tons of copper powders (both flakes and non- by-product thus formed is collected and sold to
lamellar) were imported in 2006. fertilizer manufacturers for use in making fertilizers.

According to Queneau and Gruber (1997), about Some brass mills process their own pickling solutions
13,320 metric tons of contained copper per year is to recover copper by electrolytic processes. In recent
extracted from copper-based scrap as chemicals each years, there have been several hydrometallurgical
year. The USGS (2006 Minerals Yearbook) reported plants that have thrived on processing other
copper recovered from scrap in chemical compounds companies’ sludges and residuals for copper, zinc,
as 8,214 metric tons in 2006. This copper was selenium and tellurium and other metals. A wide
produced as copper oxides and hydroxides, copper variety of metals and other products are recovered
sulfates and other copper chemicals extracted from chemical waste generated by various metal
hydrometallurgically from copper-bearing scrap. In working industries, such as printed wire board
addition, a small amount of low-grade cathode is manufacturers, electroplating shops, chemical milling
produced from electrowinning pickle liquors and operations, brass mills, and rotogravure plate
sludges. producers. Problems associated with landfill disposal
of waste materials are avoided by taking advantage of
Griffin Corp closed its secondary chemical plant in the benefits of recycling at these hydrometallurgical
Texas during 2004. At the same time, Phelps Dodge plants.
was starting a new 40 million pound, primary leach,
copper sulfate plant at Sierrita in Arizona. Waste treatment plant sludges may contain 15%
copper and a 1% to 2% zinc content. Nickel dross
Secondary Copper Byproducts. In the process of from copper/nickel alloys may run as high 40% copper
ingotmaking, fire-refining and casting of copper and its and 6% nickel, making it a valuable market material.
alloys, some low-copper or mixed scrap materials are Copper and brass drosses may run as high as 55%
generated, such as: scalper and other dusts, copper and contain notable amounts of other metals
grindings, mill scale, drosses, skimmings, ashes, such as antimony, zinc, tin and nickel. Scalper dusts
slags and other residues. Most of these residues are generated by scalpers that remove copper oxide from
marketable, or can be used and recycled at the plant mill products may also contain enough copper to be
of generation. Scalper scrap and dusts generated in recoverable and are often recycled within the plant of
the process of cleaning billet and other pure copper origin.
forms, may be entirely copper. Copper skimmings and
drosses from melting furnaces can run 20% to 65% Baghouse Dusts. Baghouse dusts are usually sold
copper and contain notable amounts of other metals for their zinc, copper and tin content. About 30% of
such as nickel and zinc. Grindings may be as much as U.S. zinc consumption (James Jolly, 1993) is derived
100% metal, and contain 10% to 76% copper. Many from all secondary materials, including flue dust
of these residues contain valuable byproducts other collected during copper alloy processing. About 86%
than copper, such as precious metals, tin, antimony, of U.S. recycled zinc in 2004 (USGS 2004 MYB,
lead, nickel or zinc, for example, which can be Table 9) was derived from the new scrap generated
recovered and upgraded. mainly in galvanizing and diecasting plants and at
brass mills. Recycled zinc was used for the production
Copper slags resulting from fire-refining can run up to of zinc metal and alloys, and zinc oxide, zinc sulfate
65% copper, making them highly desirable and and other chemicals. The Zinc Corporation of
marketable products. This is especially true of slags America’s plant in Monaca, PA, is the largest
resulting from fire-refining no. 1 scrap, where there processor of secondary zinc. Clean new brass scrap
are few, if any, associated deleterious metals. and clippings usually require only remelting. Most of
However, more metals may result in the slag than is the zinc from flue dust is recovered through various
desirable from cleaning up less pure scrap. These pyrometallurgical methods.
slags may require further metallurgical treatment to
recover the valuable by product metals. High silica Bag house dusts collected from the typical blast
slags have been used for many nonmetallurgical furnace or cupola used in melting low-grade copper
purposes when they are free of deleterious elements. scrap generally contain (Spendlove, 1961) 58 to 61%
zinc, 2 to 8% lead, 5% to 15% tin, 0.5% copper, 0.1%

19
antimony, 0.1 to .5% chlorine, and some unburned shipped as a hazardous material to another plant for
carbon. When high (about 65% zinc) in zinc and low in treatment and disposal as gypsum in a landfill. Some
lead (less than 3% Pb), these materials can be used firms specialize in treating spent sulfuric acid for
for animal feed and for making fertilizer components. disposal.
Most of the zinc oxide is shipped either in large (2,000
lb.) plastic bags (Supersaks), or in metal drums. Some The most commonly land-filled materials associated
of the zinc oxide collected, however, may be lower in with metal-making are the spent metallurgical brick
zinc (20% to 40%) and higher in some of the less and ceramic materials used for lining the furnaces
desirable elements. In this case, when they are sent when these are not high enough in metal value to
to another plant for treatment, they may be shipped as attempt recovery. These materials also must pass the
hazardous materials. TCLP tests prior to dumping. Most brass mills,
foundries and ingotmakers ship some spent furnace
Other Metal Recovery. In the process of making brick to the landfill, although some have indicated that
copper-based alloys from scrap, notable amounts of the material also may be used as road material,
other metals, such as tin, antimony, lead, zinc, nickel purchased by a scrap dealer for further distribution in
and aluminum are also recovered as part of the scrap the market, used in making concrete, or may be sold
consumed. The U.S. Geological Survey in its annual for their metal content. Some firms have indicated that
Minerals Yearbook chapter on copper reports the spent furnace brick containing significant cadmium or
average composition of secondary copper-alloy lead will be shipped as a hazardous material.
production each year. According to the 2006 USGS
Minerals Yearbook, Table 9, brass and bronze ingot Description of the U.S. secondary industry. The
production from scrap resulted in the recovery of main consumers of copper and copper-based alloy
108,570 tons of copper, 3,895 tons of tin, 5,732 tons scrap are smelters, refineries, ingot manufacturers,
of lead, 9,557 tons of zinc, 196 tons of nickel and 12 and the brass and bronze mills. Brass and bronze
tons of aluminum. Secondary metals content of brass ingot-makers and mills make cast and wrought alloys
mill products were estimated to be 719,896 tons of mainly from brass and bronze scrap. Copper alloy
copper, 1,833 tons of tin, 3,480 tons of lead, and scrap may be supplemented by other materials such
152,224 tons of zinc, and smaller amounts of other as No. 1 copper scrap, small amounts of refined
metals. In addition to 38,110 tons of copper recovered copper, and alloying additives such as tin and zinc
at U.S. foundries, 1,482 tons of tin, 1,206 tons of lead, and master alloys. According to data collected by the
2,108 tons of zinc and smaller amounts of other USGS (2006 MYB, table 7), ingotmakers accounted
metals also were recovered from copper base scrap for 9.2% of total copper recovered from U.S. copper-
sources. base scrap consumption in 2006, 67% of which was
from “old” scrap.
Items that go to the Landfill. While most low-grade
residues have traditionally found markets for further Brass mills make wrought alloys poured in shapes,
processing or use, it sometime becomes economically such as billet and slab, that are then fabricated to
impracticable to further process a material, or for finished mill products, such as sheets, tubes, rods,
economic reasons, to find a buyer for the materials. In and pipe. Brass, copper tube, and wire-rod mills
these cases, these materials are sent to a landfill. The accounted for 80% of the copper recovered from
kind of landfill selected is determined by the tests the copper-base scrap in 2006, only 1.7% of which was
materials must pass. At a minimum, all production by- estimated to have come from old scrap. Brass mills
products being sent to a land fill must pass the use purchased copper alloy scrap and No. 1 copper
USEPA TCLP test (see Chapter 4, this report) before scrap along with significant quantities of home-
a dumping permit is granted. Even so, at times, the generated scrap, refined copper, and alloying
landfilled material can serve a useful purpose at the additives such as slab zinc, lead, tin, and nickel. No. 2
landfill. For example, some brass mill slags and the and lower grades of copper scrap are usually refined
black glass residue from a slag cleaning process can before use by the mills. Copper tube mills utilize a
play an important part in the operation of the local higher percentage of “old” scrap than brass mills, but
dump as a suitable substitute for sand, which is demand a high quality number 1 copper scrap from
usually purchased and used to cover a landfill at the dealers and scrap preparers when a refinery is not
end of the day. Spent refractory and furnace brick associated.
were also used in a similar way at some localities.
Refiners use both low-grade and high-grade scrap as
Some materials, such the mildly acid water resulting raw material. Low-grade scrap is treated by a series of
from making phosphor copper shot are treated to pyrometallurgical operations followed by electrolytic
make an inert calcium phosphate sludge before being refining. The electrolytic cathodes are then melted and
landfilled. Spent sulfuric acid (pickling solutions) that cast into various shapes by the mills. Higher grades of
has already had metals removed from it may be scrap can be introduced in the later stages of

20
processing. For example, No. 2 copper is generally processed only scrap. In addition, about 23 ingot
introduced before the anode melting step that is makers, 53 brass mills, 15 wire rod plants and about
required before electrolytic refining in a tank house. 600 foundries, chemical plants and other
No. 1 copper may be either fire-refined or introduced manufacturers consumed copper scrap in the United
at the cathode-melting step, as a substitute for States. In September 1996, the Franklin Smelting and
cathode. Refineries accounted for only 4.9% of copper Refining Co. in Philadelphia, a relatively small
recovered from copper scrap in 2006, 64% of which secondary smelter with capacity to produce about
was from “old” scrap. 15,000 tons per year of blister copper closed as a
result of the high cost of environmental compliance. It
The U.S. copper industry has undergone significant soon became a superfund site (see Appendix B),
changes since the early 1980's. The extent of this along with many others of the same era.
change in productive capacity is shown in Figure 8.
Most U.S. reverberatory furnaces closed in the early Cerro Copper Products and Chemetco in Illinois and
1980's in response to environmental pressures to Southwire in Georgia once operated secondary
clean up the air, as well as to cope with the strong smelters. Chemetco produced anode for sale to
dollar and a deteriorating competitive position These others for electrolytic refining. Cerro had a completely
useful workhorse furnaces were replaced in the internal process dedicated for use in its associated
primary copper industry with flash furnaces that copper tube plants and Southwire produced copper
depend upon a high sulfur content in their feed for for use in its wire rod mill. In April 1998, Cerro Copper
efficient operation. This action not only cut the need suspended operations at its 40,000 ton-per-year
for copper scrap by the primary smelters, but it also electrolytic refinery and associated secondary smelter,
trimmed the potential capacity available for processing but still retained use of its 30,000 ton-per-year fire
low-sulfur, low-copper ashes and residues. The refinery. In 2001, the Sauget and Cahokia areas in
reverberatory furnaces also began to disappear in the Illinois were proposed to the National Priorities List
secondary industry for similar reasons. The large (NPL) of the Superfund in 2001. This site includes
secondary smelter at Carteret, New Jersey closed wastewater from Cerro Copper Company and the
during this period owing to environmental Monsanto Chemical Company (see Appendix B).
requirements and poor markets of the time. Air quality Though in 2003, there were still five secondary fire-
standards forbid the burning of associated materials to refiners, the last of the secondary electrolytic
old scrapped metal, such as plastics and circuit refineries, at Southwire, closed in 1999.
boards associated with electronic and electrical
scrapped items, making it nearly impossible to In addition to continued retraction of the secondary
process these materials by smelter. Although replaced industry in 1999, three of seven U.S. primary smelters
in part by rotary and submerged arc furnaces and also closed in response to lower copper prices and
improved air-particle capture systems, capacity has market surpluses, and remained closed through 2003.
nearly ceased in the United States for processing low- Difficult times had come for the secondary smelters,
grade copper scrap and residues. stemming from the low copper price, high cost of
environmental compliance and the cost-squeeze that
The Nassau metals facility in Gaston, South Carolina, these two had created. In 2001, the smelter at
which was based on the need to process-scrapped Chemetco closed. Chemetco also had been under suit
wire from AT&T operations, was purchased in the for potential water contamination associated with its
early 1990's by Southwire. For several years, operations. The Chemetco site was also added to the
Southwire operated both its Carrollton, Georgia and Superfund list, but was archived in late 1987. (See
Gaston, South Carolina secondary smelters and Appendix B) According to the USGS, U.S. copper
refineries. However, in 1995, Southwire closed the smelter and refinery production fell in 2000 by 42%
Gaston plant to concentrate its recycling efforts at and 26%, respectively, compared with 1998. The loss
Carrollton. In 1999, Southwire announced its intention of capacity and the effect of lower prices on scrap
to sell its Carrollton plant and, by 2000, had closed availability also impacted the availability of copper
both its smelter and electrolytic refinery associated from secondary sources.
with its wire rod plant in Carrollton, Georgia.
There continued to be generally a shortage of scrap
In 1996, there were 7 primary and 4 secondary for fire refining in 2003. Although the fire-refinery at
smelters, 8 electrolytic and 6 fire refineries, and 14 Warrenton, Missouri had closed in 1999 and reopened
primary electrowinning plants operating in the United again in 2000 under new ownership, it was to close
States. Two of the electrolytic refineries were briefly again in 2003, but was operating again in 2004.
dedicated to two of the secondary smelters; There would appear to be still a large number of
processing anode made from scrap. Several of the nonferrous foundries, but only the strongest of the
primary smelters and refineries also processed some ingot makers have done well under the difficult market
scrap and secondary anode. The U.S. fire-refiners

21
conditions of the past few years. The ingot maker of generated during production. According to the U. S.
Lavin & Sons closed at North Chicago during 2003. Geological Survey, about 75,461 tons of purchased
copper and copper alloy scrap was processed by the
Most high-grade U.S. copper base scrap is foundry industry in 2006. Foundries prefer some types
consumed at brass and copper sheet and tube mills. of scrap, such as No. 1 chopped wire, because of its
One copper wire rod mill has a direct cast operation in small size and easy melting. However, most foundries
conjunction with fire-refining its own wire mill- do not have the capability to perform smelting,
generated scrap. Although it is estimated that there refining, and chemical analysis of purchased scrap.
currently are about 53 primary brass and tube mills, it Therefore, large quantities of scrap cannot be used
is difficult to count the actual number since these have and the purchase of ingot with a known chemistry is
tended to change ownership as well as to expand the relied upon. U.S. foundries consumed 84,665 tons of
number of plants under the same company name. It is copper alloy ingot in 2006. In effect, foundries are
sometimes also difficult to separate downstream mills, remelters and producers of engineering shapes.
such as rolling mills, from those that process metal to Although 100% ingot charges may be used, charges
make semifabricates. Only plants that melt raw comprised of combined ingot, returns, and scrap are
material to make primary forms are considered not uncommon. Experience, the quantity of shop
“primary” brass or tube mills. Reroll and redraw mills, returns, and the cost of available raw materials will
or mills that operate with imported basic shapes are dictate the exact proportions.
not included in the primary mill lists.
Ingot Makers. These plants produce a wide variety of
Brass Mills. U.S. primary brass mills (a generic term copper and copper alloy and master alloy ingot for
that includes copper tube and sheet mills) have been foundry, brass mill and other industry consumption. In
concentrated in the middle and northeastern United addition to purchasing a large proportion of the "old"
States. The largest brass mills are located in Missouri copper and copper alloy scrap collected each year,
and Ohio. The following is the number of brass mills ingotmakers also purchase significant quantities of
operating in the United States, by State: skimmings, grindings, high-grade drosses and other
by-products for their metal content. There are about
Ohio (5) Missouri (1) 25 currently operating ingot makers, down from the 28
counted in 1991. Two plants closed in 2003 and 2004.
Michigan (3) Tennessee (2) The active plants are concentrated near the industrial
centers of Chicago, Los Angeles, and the eastern
Indiana (2) Alabama (1)
United States (Table 14). Ingot makers are
New York (2) Oklahoma (1) consumers of a wide variety of copper and copper
alloy materials and other metals. Most U.S.
California (1) New Jersey (3) ingotmakers are independent, largely family-owned
and operated businesses.
Illinois (4) Mississippi (2)
Wisconsin (2) Louisiana (1) Secondary Smelters and Refiners. From a total of 5
plants in 1991, there currently is no secondary
Pennsylvania (8) Connecticut (5) smelting plant operating in the United States that is
capable of processing the lower grades of copper
North Carolina (3) Iowa (1) scrap. The last operating plant in Illinois closed in
Virginia (2) Kentucky (2) 2001. There are no operating secondary electrolytic
refineries. One fire refining plant, located in
Rhode Island (1) Massachusetts (1) Warrenton, Missouri, produces refined copper ingot
and wire bar from scrap. This plant closed in early
Arkansas (1) 1999, reopening in 2000 under new management,
closed again briefly in 2003, but is currently operating.
It should be noted that reroll, or redraw mills are not Four fire-refining furnaces are associated with tube
included in the above list. and wire-rod plants, making a total of 5 fire-refineries
remaining in the United States since 2001.
Foundries. Foundries are mostly small, family-owned
operations located near major industrial centers, such Hydrometallurgical Plants. A number of plants in the
as those in Illinois, Alabama, Indiana and Wisconsin. United States have created thriving businesses based
Foundries, as a rule, do not produce alloy ingot for on hydrometallurgical processing of secondary by-
making their products. Even so, there are a few large products produced by other metal production and
foundries that have an associated ingot making metal finishing companies. Some of these companies
facility. Virtually all foundries remelt the gate scrap are listed in Table 14. Using circuit board scrap,
and the sprues, risers and rejected castings scrap bimetallics , no 2 and no. 1 scrap, most of these

22
companies produce products such as cupric oxide, themselves. Some low-grade ashes and residues are
copper sulfate, and copper carbonate. A few also imported and exported. Not shown on this chart,
companies produce low-grade copper cathode and but also important, is the significant amount of run-a-
other metal products from wastes, sludges and round, or home scrap that is used by the industry. At
pickling liquors. tube mills, this in-house scrap can amount to as much
as 30% of the material first poured to make billet and
Classic secondary copper feed for hydrometallurgical then processed to tube. Since this material generated
processing includes: within the plant can be easily remelted, or fire-refined,
much of the home scrap generated is not sold to the
• Wire choppings, mill scale, mud from wire open market. Although about 28% of the skimmings
drawing, tubing, turnings and grindings, and slag and other by-products generated are
clips and leaded cable. processed in house, most enter the purchased scrap
market. The home scrap environment is similar at a
• Scrapped brass and bronze such as brass mill that is fully integrated. The clean copper
plumbing fixtures alloy scrap generated from milling and edge trimming
operations is recycled back to the brass mill casting
• Auto radiators shop, were it is remelted and cast into cakes and
other forms for further use.
• Shredder pickings from automobiles
A current trend in response to the disappearing
• Spent etchant and pickling solutions secondary smelting industry has been the effort by
some ingotmakers and brass mills to process their
• Circuit-boards
own by-product skimmings, slag and other residues. It
has been estimated that as much as 28% of the slag
• Spent catalyst, including metallic copper
and skimmings generated are reprocessed in house.
• Waste water and other sludges (F006 Home scrap data will not appear in the published data
wastes) on purchased scrap since it never leaves the plant
and is not purchased or sold. It forms an essential part
of the production process, however, and is commonly
Metal finishing facilities. Although beyond the scope
known as run-a-round, since this is what essentially
of this paper, a brief mention should be made of the
happens. This particular scrap source goes around
metal finishing industry and its contribution to the flow
and around and is not considered a "new" source of
of secondary copper by-products. There are over
copper supply. As a useful reference, the purchased
31,000 metal finishing facilities in the United States, a
scrap data collected by the U.S. Geological Survey for
modest proportion of which uses copper products.
2006 are shown at the major points to indicate the
They vary in size, age and type of operation. Typical
gross weight quantity of scrap processed. Most of the
wastes generated include industrial wastewater and
numbers used in this flow sheet can be found in the
treatment residues (sludges), spent copper plating
tables included with this report. Others are published
and process baths, spent cleaners and waste solvents
in various U.S. Geological Survey reports (Minerals
and oil. The metal-laden sludges (F006 wastes)
Yearbooks, Mineral Industry Surveys).
generated at these plants provide a source of copper
and other metal raw material for some
hydrometallurgical recovery plants. As a point of interest, it can be noted on the flow sheet
that about 3.2 million tons of mill and foundry products
equate to about 1 million tons of new scrap returned
for use in 2006. These figures would indicate about a
32% return of mill products as new scrap. Exports on
Flow of Materials this diagram are presumed to be mostly old scrap,
since the amount of old scrap consumed by the
Summary of scrap flow. The chart in Figure 9 shows domestic industry has decreased significantly in
the flow of purchased secondary copper-base recent years. Most of the facilities that once
materials from the various sources to the final processed significant quantities of old (end use) scrap
manufacturing destination. The chart traces the scrap have closed and, in large part, this scrap is being
flow from old and new, unalloyed and alloyed, and exported. Chemical products are generally used and
low-grade copper scrap types as they are processed dissipated. Copper sulfate is the only chemical
from sources through secondary smelters, refineries, product shown in this flow diagram.
ingot maker, brass mills, foundries to final products.
The domestic sources for low grade ashes and
residues are the processing facilities (ingotmakers,
secondary smelters & refineries, brass and wire mills)

23
CHAPTER 2: Since then, however, copper recovered from total U.S.
scrap consumption has dropped to around 950,000
Overview of Scrap Sources tons per year between 2003 and 2006. In addition to
and Types the many copper and copper alloy scrap types, there
are many special types, such as skimmings, ashes,
refining slags and residues, which contain 10% to
65% copper. Copper may also be recovered from
other mixed scrap of lower copper content, such as
Scrap Sources and Types electronic scrap, printed circuit and other clad
materials, and metal-laden waste liquors. The markets
The Institute of Scrap Recycling Industries, Inc. (ISRI) for these products are different from those for the
recognizes about 53 classes of copper and copper purer grades of copper-base scrap, because they
alloy scrap. The organization publishes a scrap must be reprocessed, smelted or electrowon to obtain
specification circular that details guidelines for the valuable metals contained in them. In the market,
nonferrous scrap. Although there are several grades products of less than 65% but higher than 10%
within each, the major unalloyed scrap categories are copper, including refinery brass and low-grade
No. 1 copper (common names – Barley, Berry, Candy copper-containing materials, have been traditionally
and Clove), which contains greater than 99% copper processed by copper smelters and refiners or ingot
and often is simply remelted, and No. 2 copper makers.
(common names – Birch, Cliff and Cobra), which
usually must be re-refined. No. 2 copper consists of Several terms have been applied to copper-containing
unalloyed copper having a nominal 96% copper materials with less than 65% copper but more than
content (minimum 94%) as determined by assay. 10% copper. The U.S. Department of Commerce
Light-copper scrap (Dream) contains between 88% trade classifications describe this material as “metal-
and 92% copper. All grades are clear of excessively bearing materials used for extraction of metal, with
leaded, tinned or soldered copper scrap and bronzes chief weight of copper” (prior to 1989), and “copper
and brasses, etc. Refinery Brass has a minimum of materials containing over 10% copper” (since 1989),
61.3% copper and maximum of 5% iron and consists but they are not listed under primary ores and
of brass and bronze solids and turnings, and alloyed concentrates. These materials are commonly called
and contaminated copper scrap. Copper alloy scrap of copper-containing ashes and residues as a general
various types may be classified by alloy type, or by group, but they contain a wide variety of products that
end-use derivation, since certain alloys are are generated as by-products of copper and copper
consistently used for the same machine part or other alloy metal manufacture. In examining the trade lists,
useful item. For example, composition or red brass it is impossible to distinguish between skimmings,
scrap derived from valves, machinery bearings and residues or slags containing copper. It becomes even
other machinery parts is used again for making similar more difficult in the international trade arena with the
cast items. Red brass scrap should be free of semi- earlier SITC (Standard Industrial Trade Classification)
red brass castings (78% to 81% copper), railroad car codes used by the United Nations, which contain
boxes and other similar high-lead alloys. Table 15 other products lumped together with the copper items.
shows a list of generalized chemical compositions for
various scrap types.

Several alloy scrap type groups, such as mixed EPA Secondary Product Definitions
unsweated auto radiators (Ocean), provide sizeable
amounts of copper scrap each year. Other important The U.S. Environmental Protection Agency (EPA)
sources of scrap, by volume, include cartridge cases plays such a big role in how the secondary industry
(70/30 brass) from the military and other yellow brass carries out its business, it is worth reviewing that
castings, rod turnings and rod ends. Significant agency’s definitions for secondary products.
amounts of unalloyed copper are derived from According to the EPA (40 CFR Chapter 1 (7/1/98 Ed.)
discarded wire, busbars, clippings and tube. A (261.2)), a material such as process slags and
relatively new scrap type, derived from residues is reclaimed if it is processed to recover a
aluminum/copper radiators, also is finding use among usable product, or if it is regenerated. A material is
scrap remelters. As shown in Table 16, copper used or reused if it is either:
derived from new and old aluminum-based scrap has
been increasing significantly since 1980. Copper from (1) Used as an ingredient (including as an
aluminum-based scrap increased from about 35,000 intermediate) in an industrial process to make a
tons in 1980 to around 68,290 tons in 2006. Copper
product. However, a material will not satisfy this
from all scrap sources increased from 886,000 tons in condition if distinct components of the material are
1950 to a peak of nearly 1.5 million tons in 1997. recovered as separate end products. For

24
 example, this is the case when metals are are considered as commercial chemical products;
recovered from secondary materials. used circuit boards are spent materials; and circuit
board trimmings are by-products. The unused circuit
(2) Used in a function or application as a substitute boards are secondary materials. Under 40 CFR 261.2,
for a commercial product such as sludge the Agency designates those secondary materials that
conditioner in wastewater treatment. Scrap metal are RCRA Subtitle C solid wastes when recycled.
is defined as bits and pieces of metal parts. This According to Section 262.2 (c) (3), unused off-
includes turning, bar, rod, sheet, wire or metal specification commercial chemical products listed in
pieces that may be combined together with bolts 40 CFR 261.33 are not considered solid wastes when
or soldering (car radiators, etc.) that can be sent for reclamation. They are considered to be non-
recycled. listed commercial chemical products and, thus, not
solid wastes when reclaimed. The printed circuit board
A material is a by-product if it is not one of the primary trimmings meet the definition of by-product, rather
products of a production process and is not solely, or than scrap metal, and are not solid wastes when
separately, produced by the production process. reclaimed under Section 261.2 (c)(3). Although the
Examples are process residues such as slags. The trimmings are physically similar to scrap metal, to
term does not include a co-product that is produced meet the definition of scrap metal, the material must
for the general public’s use and is ordinarily used in have significant metal content; i.e., greater than 50%
the form produced by the process. A spent material is metal.
any material that has been used and, as a result of
contamination, can no longer serve the purpose for Home scrap is scrap metal as generated by mills,
which it was produced without further processing. foundries and refineries, such as turnings, cuttings,
punchings and borings. Prompt scrap is metal as
A material is recycled if it is used, reused or generated by metal working and fabrication industries.
reclaimed. A material is accumulated speculatively if it It includes scrap such as turnings, cuttings, punchings
is accumulated before being recycled. It is not and borings. Prompt scrap is also known as industrial
speculative, if it can be shown that there is a feasible or new scrap metal (See FR 83119, May 19, 1990,
means available for recycling it. There is a 75% and amendments through May 12, 1997 (FR 26018).
turnover requirement for recycling The amount of
material that is recycled or transferred to a different By not distinguishing adequately between home
site for recycling must equal at least 75% by weight or scrap, runaround scrap and purchased scrap, EPA
volume of the amount accumulated starting on has not recognized the market potential of all scrap
January 1 of the period. The 75% requirement is generated. When a scrap or by-product of any type
applied to each material of the same type that is leaves the plant for a market, it becomes purchased
recycled in the same way. Materials are no longer in scrap. Purchased scrap of all types is traded at all
this category once they are removed from levels of the industry. Home scrap, or runaround scrap
accumulation for recycling. is completely contained and never leaves the plant.

Excluded scrap metal is processed scrap metal,

unprocessed home scrap metal, and unprocessed
prompt scrap metal. Processed scrap metal is that Consumption by Scrap Type.
which has been manually or physically altered either
to separate it into distinct materials to enhance According to the U. S. Geological Survey, the major
economic value or to improve the handling of said copper-base scrap types consumed in the United
materials. Processed scrap metal includes, but is not States during 2006 were: No. 1 copper, (42%); No. 2
limited to, scrap metal that has been baled, shredded, copper (4%); yellow and low brass (32%); automobile
sheared, chopped, crushed, flattened, cut, melted or radiators (2.7%); red brass (3.5%); cartridge brass
separated and sorted by metal type. It also includes (8.2%); and low-grade ashes and residues (3%) (see
fines, drosses and related materials that have been Table 17B). A wide variety of other alloy scraps
agglomerated. Shredded circuit boards being sent for makes up the remaining 4.6%. Brass and copper
recycling are not considered processed scrap metal. sheet, wire and, tube mills processed 82% of the No.
They are covered under the exclusion from the 1 copper and most of the cartridge cases and yellow
definition of solid waste for shredded circuit boards brass, while the fire refiners and ingot makers
being recycled. (261.4(a) (I3). processed 62% of the No. 2 scrap and most of the
auto radiators and red brass scrap. About 22% of the
In a document issued March 1, 1990, EPA clarified scrap consumed in 2006 was lead-bearing, including
the reclamation of unused, off-specification printed auto radiators using lead solder (31,139 tons), red and
circuit boards. When reclaimed, unused printed circuit leaded-red brasses (40,107 tons) and leaded-yellow
boards (30% copper, 68% fiberglass, 2% tin and lead) brasses (185.935 tons).

25
In recent years the amount of No. 2 scrap reported as added to the domestic consumption of 4,000 tons per
consumed by the U.S. industry has been decreasing. month for a total of 31,000 tons per month of number
The decrease in No. 2 scrap consumed by U.S. 2 scrap, compared with an estimate of 32,000 tons
industry is related to several changing factors. One per month that was common domestic consumption
such factor is the significant increase in better quality some 10 years ago.
wire and cable recovery by scrap choppers and
processors. More chopped wire is converted to No. 1 Not surprisingly, China imported 85% of the number 1
scrap quality than has ever before been possible, scrap and 67% of the number 2 scrap exported from
owing both to an increase in this type of activity and to the United States in 2005. South Korea and Taiwan
better technology. Other factors include the lower followed with 3% - 7% each of unalloyed scrap
prices of 1998-2003 (Table 1) and increased export imports from the United States.
competition for such scrap in more recent years.
A few trends in consumption rates, shown in Table 17
The consumption of No. 2 scrap decreased markedly and in Figure 10, for certain types of scrap are worth
at U.S. plants since 2002, as a result of secondary mentioning. The amount of auto radiators (does not
smelter and electrolytic refinery closure. Some primary include aluminum/copper radiators) consumed by the
smelters have been accepting limited tonnage of No. U.S. industry has ranged between 31,000 tons and
2 scrap. However, apparently, scrap exports were 104,000 tons per year year since 1970, with the peak
filling the gap left by the loss of U.S. capacity, as occurring in 1988. That amount has been steadily
discussed in the previous section on international decreasing since 1988 to the current rate of around
trade. It has been difficult to quantify the total volume 29,000 tons. Yellow (including leaded-yellow) and low-
of No. 2 scrap recycled each year, since the only brass scrap consumption steadily increased through
statistics reported for the United States are 2000. Since 2000, however, yellow brass
consumption-based. Scrap traders are not surveyed. consumption has decreased to only 362,000 tons in
Adding exports to the No. 2 scrap consumption 2006. The yellow brass categories were lumped
statistics also is not a certain solution to compensate together in Table 17 to allow for possible definition
for the apparent loss, since these materials have not changes over the period of statistical collection
been always specifically defined as to type in trade between types of yellow brass scrap. The amount of
statistics. One might use a percentage calculation bronze scrap consumed has ranged between 18,000
applied to the unalloyed copper scrap exports based tons and 32,000 tons per year since 1970. Although
on the ratio of No.1 to No.2 consumption for the years aluminum bronze scrap has remained at a more or
before the demise of the smelter industry. In 1988, the less constant rate of consumption, the number of
ratio of No. 1 to No. 2 scrap consumed by the U.S. plants using it has diminished, resulting in this statistic
industry was about 1:1, but the ratio has been being withheld by the government statistical collectors
deteriorating since that time (see Table 17). In 1990, since 1991. Cartridge brass consumption reached
No. 2 was 45% of total unalloyed scrap consumed. 131,000 tons during the last three years of the
Using 45% applied to 2004 exports (325,000 tons) of Vietnam conflict (1970–1973). Since that time,
unalloyed scrap yields a total of 146, 250 tons of cartridge brass consumption has remained in the
number 2 scrap exported. Recent data indicates that range of 46,000 tons to 94,000 tons, with the
the percent of number 2 scrap exported in 2004 was exception of the 1988–1990 period, when
much higher. consumption reached as high as 140,000 tons during
a time of temporary military buildup for Desert Storm.
Recent U.S. trade reports have been breaking down The slight increase in cartridge brass consumption
scrap types exported. The Harmonized Trade (HTS) from a low of 36,000 tons in 2001 to a high of 94,000
items were recently reviewed and revised by the U.S. in 2006 may be the result of the military activity in Iraq
government. HTS 7404000020 (waste and refined and Afganistan. In 2002, cartridge brass consumption
scrap from refined copper) has been broken into two nearly doubled to 70,900 tons from the low point of
Number 1 scrap categories (HTS 7404000010 and -- 36,400 tons in 2001. Cartridge brass consumption
15), two Number 2 scrap categories (HTS was 86,000 tons in 2004 and more than 94,000 tons
7404000025 and –30). The results of the new trade in 2005 and 2006.
breakouts are shown for 2005 to 2007 in Table 8A of
this report. From this table, it can be seen that The amount of marketed low-grade scrap processed
Number 2 scrap comprises a larger share of the in U.S. plants has been decreasing since 1985, as
unalloyed scrap exported. Of the total of 399,029 tons indicated by data collected from the industry by the
of unalloyed scrap exported in 2006, Number 2 scrap U.S. Geological Survey and U.S. Bureau of Mines
comprised 83% of the total. About 260,000 tons of (Table 17 and Figure 10). While the amount of low-
number 2 scrap was exported in 2005 and for the first grade, copper- bearing materials consumed in 1998
9 months of 2007. These scrap exports yield an and 1999 was marginally higher than the previous 4
average of about 27,000 tons per month that can be years, it still was only one-third that of the 1970s and

26
 Figure 10: U.S. Copper and Copper Alloy Scrap
Consumption, by General Alloy Group

Thousand Metric Tons, Gross Weight

2400

2100

1800

1500

1200

900

600

300

72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 00 01 02 03 04 05 06 07
19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 20 20 20 20 20 20 20 20

Unalloyed Red Brass Yellow Brass 1/ Cartridge Brass Bronzes

Low-grade scrap 2/ Auto Radiators Nickel Silver

1/ Includes yellow brass, leaded yellow brass and low brass.

2/ 20%-65% copper. Refinery brass is excluded.

Source: U.S. Bureau of Mines, U.S. Geological Survey Minerals Yearbooks and Mineral Industry Surveys

early 1980s. Low-grade scrap and residues consumed relationships in the next section on life cycles and the
annually in 2002-2007 was only 35,000 tons, down scrap reservoir.
significantly from 124,000 tons in 1998. This
compares with 161,000 tons per year of low-grade In 2006, (USGS, 2006 Minerals Yearbook, table 6)
scrap and residues processed in the United States in recycled copper was derived 85% from purchased
1992 and 1993. new scrap generated in the process of manufacture
and only 15% from old scrap derived from used
Scrap consumption was lowest during the recession products. Copper from scrap recovery exceeded l
years of the middle 1970s, early 1980s, and again in million tons per year in 1965 and continued to be
2001–2003. Some of the underlying causes for these above this level through 2002, dropping to 800,000
trends are discussed in Chapter 1 and in Appendix A. tons in only one year (1975). Copper recovered from
In particular, lower copper prices and the closure of scrap has been well below 1 million tons since 2002
adequate processing capacity for domestic copper- (Table 6).
bearing scrap has been responsible for many of the
observed declining usage trends. In recent years, According to the U.S. Geological Survey, a total
foreign competition for U.S. scrap materials also has 968,500 tons of copper was recovered from copper
been a considerable factor bearing on the reduction in base and non-copper-base scrap in 2006. A similar
scrap consumption by U.S. industry. amount is estimated in for 2007, based on 8 months
of reported data. Purchased new scrap derived from
fabricating operations yielded about 827,387 tons of
contained copper, 91% of which was recovered at
Volumes of Scrap Generated brass mills. A manufacturer may generate more than
60% scrap in the form of slippings, trimmings,
Since 1906, at a rate ranging between 10,000 tons stampings, borings and turnings during the processing
and 1.6 million tons per year, the calculated U.S. of copper and copper-base products into finished
cumulative consumption of copper from old and new articles. This new, or mill-return, scrap is readily used
scrap amounted to 81 million tons by 2007. Of this by brass and copper tube mills to generate new
amount, 43% (35 million) was from old recycled scrap. semifabricates. Secondary materials that require
More will be discussed about these statistical minimal processing commonly are called direct-melt
scrap. In the United States, direct-melt scrap provided

27
about 907,000 tons (Table 2C), or about 94% of The data in Table 17 show a distinct reduction in U.S.
copper from all secondary materials in 2006. New consumption of low-grade material as purchased
scrap made up about 26% of U.S. apparent scrap beginning in the early 1980s. Reduction in the
consumption of copper from all sources (primary and use of low-grade material for industrial feed coincides
recycled) in 2006 (see Table 6). Copper in old and with several events over the period: (1) capacity
new scrap together comprised about 31% of U.S. cutbacks and decreased use of reverberatory
apparent total copper consumption in 2006. furnaces by the primary copper industry, and (2) the
closure of secondary smelters. The increased use of
The U.S. Government (U.S. Bureau of Mines and the flash furnace technology by the primary industry,
U.S. Geological Survey) has long collected data from which relies on a high sulfur content of the ores
plants consuming purchased low-grade scrap and processed to maintain a high heat, has lessened the
residues. By current definition, this material is use of low-grade scrap by the primary industry.
comprised of copper-bearing ashes, residues, Previous primary smelters, such as the AMAX smelter
drosses, skimmings and other materials of less than at Carteret, New Jersey, were significant consumers
65% copper. Long-term trends (Table 17) for this of low-grade scrap and residues prior to the 1980s.
statistic, however, are complicated by the fact that the Low-grade scrap, residues and slag are currently
definition has changed subtly several times. Material exported or consumed by the several ingot makers
that might more appropriately be classified as refinery who may have cupolas, reverberatory or other
brass or a higher-grade copper material, but less than furnaces adequate to handle these materials. In the
65% copper, may also be included in the reported 1970s, the U.S. smelting and ingot-maker industries
numbers from time to time. In addition, some slags were consuming 300,000–500,000 tons of low- grade
and residues from primary copper processing may scrap and residues. This compares with a rate of
have also been included in some of the historical data. about 80,000–100,000 tons in the 1990s, and only
It also should be emphasized that this number reflects 35,000 tons per year since 2001. Special surveys
only the marketed component of this material as it is were made by the Copper Development Association
consumed, it does not count the same material as it is in 1994, and again in 1999, for by-product information.
generated and reused as home scrap. It also does not The combined response rate for the two surveys was
include exported materials. about 72% for the brass mills, 62% for the ingot
makers, and about 15% for the foundries, based on
The purchased scrap market for domestically shipped, the total production for each group. The data were
low-grade copper ashes and residues may be aggregated by industry group and matched with
estimated by using a formula that adds exports to the similarly aggregated production data provided by the
amount reported as consumed and, then, subtracts U. S. Geological Survey. The result was statistically
imports to eliminate the foreign component. Using this adjusted to derive a full industry estimate for 1998.
procedure, the domestic industry low-grade scrap While most fire refiners were included in this survey,
shipments are estimated to have ranged between two of the secondary smelters were not. It might be
31,000 tons and 169,000 tons gross weight per year presumed that most of the low-grade residues
over the last 12 years (Table 9). Copper content of produced by these firms are recycled in-house.
this material ranged between 11,000 tons and 60,000
tons per year. This is the approximate size of the It is interesting that the total production of these
purchased scrap market within the low-grade copper products, as shown in Table 18, is similar to the total
scrap category. These statistics do not include any of low-grade, purchased ashes and residues scrap data
the materials that are processed in-house as tracked by the U.S. Geological Survey. This
runaround scrap. Both exports and domestic observation lends credence to the reliability of both
consumption reported for low-grade residues have sets of data. The total by-product production shown in
diminished in recent years, especially since 2001. In Table 18 is larger than the purchased scrap data of
part, this is a result of secondary plants recycling the USGS, owing to the fact that some home or
more of this type of material internally. It is also runaround scrap is included in Table 18, but not in the
partially the result of new production methods that USGS data. It was estimated that at least 28% of the
have been implemented specifically to cut down on skimmings and slags are recycled in-house, as
the volumes of residues created. The goal is, indicated by the reports.
generally, that only the most innocuous and
uneconomic material will leave the plant for a landfill Not surprisingly, the brass mill group (including tube
or purpose other than metal recovery. The severe mills, wire rod mills and their associated refineries)
drop of recent years in U.S. low-grade residues was the source for most of the by-products surveyed.
consumption also reflected the closure of the last U.S. Next in size, and commensurate with its share of
secondary smelter in 2001. scrap consumed and types of processing, was the
ingot maker group. Though their numbers are many,
the total amount of by-products generated by copper-

28
base foundries is small compared with the rest of the babbitt in tin scrap), and trace Al and Si. Also added
secondary processing industry. were 2000 pounds of zinc, tin and lead metal, and
4,000 pounds of flux. From this mixture, about
A wide variety of by-product materials were reported, 178,000 pounds of brass ingot resulted, with a 93%
not all of which could be classified into uniform metal recovery rate. In addition to the ingot, about
product groups. Reported drosses included a variety 10,000 pounds of slag was produced as a by-product.
of copper, nickel and brass drosses. Other products The slag had an average composition of 20% zinc
included in other residues of Table 18 are copper oxide, 20% iron oxides, 35% silicon dioxide, 20%
residues from refinery and pickling processes, water copper prills, 5-8% copper oxide and small amounts of
pit and other sludges, anode recovery solids, machine cadmium oxide, magnesium oxide, and aluminum
shop turnings, cupola flue cleanout, afterburner dusts, oxide. Estimated losses, gases, dust and other
scalper dusts, other reclamation dusts, metal residues amounted to 1,600 pounds.
skimmings, mill scale, and copper cathode recovered
from pickling solutions. Of all the products reported, Spendlove (1961) also reported that in producing 85-
very few were indicated as being sent directly to a 5-5-5 red brass ingot from a 50 ton-per-day rotary
landfill; most firms were able to find some market or furnace, the following charge is typical: 50.3% red
other processor that could accept it as useful material. brass solids, 18.5% red brass borings, 13.7%
Most were sold to ingot makers, secondary U.S. and radiators, 7.6% light copper, 3.9% hard brass borings,
foreign smelters, hydrometallurgical plants, concrete 3.7% spatters, 0.5% scrap lead, 0.1% phoscopper
makers and zinc smelters, or they were shipped for and 1.7% nonmetallic. The following can be expected
direct use as agricultural products and animal feed. to be produced from this charge: 89.8% red brass
ingot, 7.2% slag, 1.8% splatters and 1.2% losses
The zinc oxide dust reported in this survey was (gases, dusts, etc.).
shipped to zinc processing and smelting firms such as
Zinc Corporation of America, Big River Zinc, M&M
Metals, Phillip Environmental Services, American
Micro Trace and the Horsehead Resources Use of Home Scrap
Development Co. The zinc oxide was most often
shipped in 55-gallon steel drums by truck. However, At Brass and Wire Mills. All copper and brass mills
some companies prefer to ship zinc oxide in 2,000- use home scrap derived in the process of making
pound plastic bags (supersaks). Most zinc oxide is wrought products. Considerable home scrap can be
sold; very few reported the occasion to dump it. derived from the process of making brass or tube mill
products. Whether or not the scrap is used for direct
Secondary smelters such as Chemetco, and Franklin melt back into the melting furnace depends upon its
Smelting and Refining (both of which are now closed) character at the time of collection. Dirty or
were significant purchasers of furnace slag and contaminated scrap cannot be used directly, but good,
skimmings shipped. Some of this material also was clean scrap of known composition can be, and is
exported to Noranda in Canada. The furnace slag and used. Most home scrap generated within the brass
skimmings ranged between 8% and 65% copper, up mill or copper tube plant is reused in house and also
to 6% tin, up to 25% zinc, and less than 5% lead. is called runaround scrap. As much as 30% of the
Spent furnace brick is often sent to the landfill, but it material poured for making tube ends up as home
generally contains less than 1% of all elements (Cu, scrap generated in the process of making tube. This
Sn, Zn, Pb, Cd) analyzed and, thus, does not require material is reprocessed in a fire refinery at the plant
special permits for handling. The only products when one is available. When pure enough, such as
shipped as hazardous included some low-grade metal scalper residues from cleaning billets and tube ends, it
oxide dust, baghouse dust and some furnace and can be put back into the production process directly. It
refractory bricks. Elements such as cadmium and lead is otherwise sold as No. l or No. 2 scrap for
usually caused the product to be classified as processing and use outside the plant of origin. Wire
hazardous, when these were present in significant mills must be more particular with in-house-generated
amounts. scrap, requiring a fire-refining step before
reintroduction to an Asarco shaft furnace for recasting.
The average product yield from certain melts were the Items such as flue dusts, drosses and other minor
subject of a 1961 U.S. Bureau of Mines research materials generated are not usually runaround, since
report (Spendlove, 1961). According to this study, the these items may be shipped to other companies for
following products may be expected from processing reprocessing. Home scrap ceases to be runaround
190,000 tons of brass and copper scrap in a tilting, scrap when it is sold to another plant for further
cylindrical reverberatory furnace. The melt had the processing. The scrap is then referred to as new
following average composition: 84.5% Cu, 4.4% Sn, purchased scrap, entering the secondary materials
5.25% Pb, 5.4% Zn, 0.15% Fe, 0.22% Sb (from

29
market for trade. The marketed drosses, skimmings reasonably reliable. However, in some cases, it will
and other residues are new purchased scrap. not have been properly sorted and, therefore, if used
directly, could result in contaminated heats. The
At Secondary Smelters and Refiners. The by-product increased use by the U.S. consumer of imported
scrap generated at smelters and refiners, such as faucets, tube and other products made from foreign-
slag, flue dusts and spilled metal, can be partially or made alloys has increased the need for constant
wholly reprocessed in-plant. Some, such as the flue vigilance of the scrap purchased. Most ingot makers
dusts generated, must be sold or shipped to other and mills must have sophisticated procedures for
facilities for treatment and disposal. Slag is often sold analyzing purchased scrap, adding to the cost of
into a direct use market, but depending upon its metal using this material. Purchased customer-returned
content, may also be reprocessed in the home plant, scrap to brass mills can usually be presumed reliable
sold to other smelters or locally landfilled. Some slag for direct melt, but even these must be closely
resulting from fire refining of scrap can contain as monitored. Product specifications call for a very low
much as 65% copper and, thus, is a very desirable content of certain elements, such as aluminum and
and marketable product. silicon. In the red brass series, for example, the
maximum acceptable levels of aluminum and silicon
At Foundries. Every foundry generates scrap returns are 0.005% and 0.003%, respectively. Meeting these
from gating systems, risers, and occasional scrapped specifications is achieved by controlling the
castings. A shop with its own machining and stamping composition of the scrap charged to the furnace.
operation will also produce considerable quantities of Impurities such as iron, sulfur, cadmium, bismuth,
turnings and borings. It is common practice to absorb phosphorus and manganese can be removed by
these materials in the melting operation as a portion of various techniques involving oxidation and the use of
the charge makeup, rather than to use a 100% return slags.
charge. However, gates and risers from sand castings
may not be completely clean of mold materials and
other contaminants; turnings may be covered with
cutting fluids; residual deoxidizers or impurities may Life Cycles and the Theoretical
be building up in the return materials. Each of these Resource for Scrap
can contribute to casting defects and are not normally
used without preparation. With successive remeltings,
The availability of secondary copper is linked with the
there will be a decided trend toward the gradual loss
quantity of copper consumed and product life cycles.
of volatile elements, such as zinc, as well as an
Many estimates for life cycles have been made for
accumulation of contaminants, such as iron.
individual products. Product life cycles may even vary
Depending upon melting and subsequent
from country to country according to construction
deoxidization practices, the level of residual
methods and concepts. However, copper in electrical
phosphorous in the melt may rise to undesirable
plants and machinery generally has been estimated to
levels. Thus, a consistent monitoring of internal scrap
average 30 years; in nonelectrical machinery, 15
composition should be made before reuse. A
years; in housing, 45 years; and, in transportation, 10
particularly serious contaminant in the case of copper-
years. The average useful life for copper products is
tin-lead-zinc alloys is aluminum. Unfortunately,
said to be about 25 years before being scrapped and
aluminum beverage cans and foil wrappers may
entering the market as old scrap.
accidentally find their way into the charge material.
When this happens, not only are serious problems
Keeping these longevity measures in mind, it is not
generated in the melt, but also such metals must be
hard to visualize that copper being recovered today is
discarded and resold to a smelter, since their reuse
from scrapped items that were produced for use about
could cause the same problems over and over. Many
25 years ago. New (manufacturing) scrap, on the
foundries restrict the use of these materials to
other hand, has a short life of about 30 days, and
confined areas.
domestic manufacturing rates and efficiencies limit its
recovery. This wide difference in turnaround and
availability, in addition to the growing manufacturing
base from which it is generated, has resulted in a
Use of Purchased Scrap gradual increase of new scrap versus old scrap
collected in the United States since the 1930s (Table
When purchased scrap is used, a complete analysis 6). The rate of copper consumption in the United
of each melt is necessary to assure freedom from States and the world has more than doubled since the
contamination. Some forms of purchased scrap are 1960s. Scrap copper (old and new) has made up
relatively reliable such as heavy copper wire, bus bar more than 40% of annual U.S. copper consumption
or automotive radiators. Obsolete old scrap from over most of this period, only dropping below 40%
certain sources and applications also may be

30
since 1993 (Table 6). The current downward trend in reported for the United States. The rate of old scrap
scrap copper is coincidental to the significant increase recovery (including exports) from the calculated
in consumption of primary (mined) copper since the primary copper end-use resource has been
early 1990s, and the lower copper prices 1998 decreasing since a peak of 54%, which was reached
through 2003. Scrap comprised only 31% of total U.S. 1991- 1993.
copper consumption in 2006.
The rate of old scrap recovery is limited not only by
Though copper is one of the most recycled of metals, copper’s long life and its essential uses, but also by
some still enters solid waste disposal sites. Copper the sensitivity of scrap collection to market prices.
that is not recovered from end-use products may be When copper prices are depressed, old scrap tends to
placed in one of three categories: (1) still in use, or be less available and is directly related to the cost to
buried and unaccountable, (2) solid waste disposal, recover and process it. The distinct decrease that is
(3) dissipated and lost. Recovery of copper from the observed in the old-scrap to new-scrap recovery ratio
first two categories is always possible with adequate since 1990 (Table 17B) has more than a price
incentives and technology. Copper has few relationship attached to it. Since the closing of all
applications that are dissipative in nature, such as in secondary and primary copper reverberatory smelters
chemicals, paints and some powders. It has been occurred over this time period, one can only assume
estimated (Carrillo, 1974) that in 1970 only 0.5% of that the sharp drop off in consumption of old scrap
total copper consumed was lost and not retrievable. over the same period is related to the decrease in
Most copper is used in some metal form, easily adequate processing capacity in the United States.
recognizable and easily recoverable. Some household Once sought out for its metal content, this material is
products such as toasters, motors, TVs, electronic either being exported, or it is not being collected for
equipment, etc., may have been dumped into landfills consumption. U.S. copper and copper alloy scrap
in the past, rather than collected or sold for their metal exports have increased significantly in recent years
content. However, with the current emphasis on the and might logically be presumed to be mostly old
selection of household and municipal-dump items for scrap. At the same time, new scrap recovery has
recycling, the amount of copper actually placed in a been increasing at a rapid pace in tandem with the
landfill is probably not only small, but is diminishing. higher rate of copper consumption and manufacturing.

The variances in estimates for the amounts recycled Resource Theory and Calculations. Primary (mined)
are directly related to a lack of reliable data as well as copper forms the only contribution to a theoretical
to the procedures used for making the estimations. accumulating resource base. Most of the copper ever
Because time is always a factor, it has been difficult to extracted from the earth can be determined by using
quantify how long a product has been in use and how primary copper consumption or production statistics
much of it was recovered over what time period. that have been collected and published over time.
Some have estimated copper not recovered to be as However, scrap, old or new, is excluded as a primary
high as 50% of all products reaching the end of a constituent of the theoretical resource base, since no
useful life. However, other estimates have suggested new (primary) copper can be generated from it.
that the recovery (recycle or reuse) rate may be in
excess of 70% for copper products no longer in use. According to McMahon (1965), a large reserve for
Because, generally, it has been cost effective to secondary (recyclable) copper, in the form of
collect, prepare and sell copper-base scrap over recoverable end-use products, has been accumulating
recent years, a much higher percentage of copper in the United States and in the world. This end-use
may be recovered from outcast products than may resource is continually being augmented because of
have been previously estimated. It is widely known consumption patterns and the indestructibility of
that it may not be cost effective at all times to recover copper. Each year, copper in the form of old scrap is
some buried cable and pipe, and, thus, it may remain recovered from this reservoir. In the United States, old
buried for years. Even so, the metal is not destroyed scrap copper recovery in 1960 comprised about 21%
or dissipated and may eventually be reclaimed, if of annual consumption, but more recently it has been
recovery cost and incentives are right. much lower. Not counting old scrap in exports, old
scrap comprised only 7.4% of U.S. apparent
The estimated resource calculations made below, and consumption in 2006 (USGS, Min. Industry Surveys,
in Table 6A indicate that more than 65% of total Feb. 2007).
primary copper consumed in the United States has
been returned and reused as new and old scrap over In 1960, McMahon also estimated about 25% of
time. This calculated scrap recovery rate was as high annual consumption was new scrap that was
as 70% between 1989 and 1994, but has dropped generated from fabricating and manufacturing
currently to around 65%. This change undoubtedly is semifinished and finished products. McMahon
related to the drop in old scrap consumption, as recognized that new scrap copper does not form a

31
 Figure 11. U.S. and World Copper Resource
for Old Scrap
Pool of Copper Materials In Use

Million Tons, Copper Content

350
309 million in 2007

300

250
World Trend
200

U.S. estimated =
150 100 million in 1972
88.4 million in 2007

100 45 million in 1975

    


        U. S. Trend




  
50





 U.S. Actual =83.1 million in 2007








0

4 0 43 4 6 49 52 55 5 8 61 64 6 7 70 73 76 7 9 82 8 5 88 91 94 9 7 00 03 06
19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 20 20 20
Years
USEstimated World USActual
Sources: JJolly, Jan. 2008. McMahon, 1965
World Resource= Copper mine production increase less 40% deducted for: recirculating scrap(25%) and process losses (15%)
U.S. estimated Resource= Primary copper consumption increase less 25% for annual recirculating copper.
U.S. Actual resource = Primary copper consumption increase less annual reported new scrap generated (1864-2007).

reservoir supply to supplement production of primary the U.S. industry’s contribution to the secondary
copper. New scrap such as defective castings, materials reservoir of items in use, or abandoned in
clippings, punchings, turnings, etc., represents a place, has increased from about 14.5 million tons in
circulating quantity of copper previously accounted for 1940 to around 89 million tons in 2007 (see Figure
as a supply of primary copper and returned to the 11). According to McMahon (1965, Table 10, p.75),
fabricating process without reaching the product about 52% of the end-use reservoir so calculated had
stage. It is, in effect, 100% recycled. Even so, data on been returned and reused as old scrap by 1960.
the movement of new scrap have significance as
indicators of business activity in the fabricating and McMahon’s method for estimating the world resource
scrap reclamation industries. involved a simple ratio equation based on the
assumption that the rest of the world consumes
The resource estimation procedure adopted by copper in much the same manner as the United
McMahon deducts an estimate of 25% annually from States. Using this formula with cumulative world
the cumulative series of primary copper consumed. copper consumption, as McMahon suggests, yields
McMahon (1965, Table 10, p. 77). The estimation some 314 million tons of copper for the resource base
procedure also purposely does not include old scrap in 2002. This estimation is a little too high, however,
in the calculations. Although McMahon does not because the consumption statistics used for the world
specifically identify the 25% deducted for unused include copper from scrap.
primary copper as new scrap, it is here presumed to
be the case, based on his detailed description of Since imports and exports between countries are not
scrap relationships. In other words, he presumes that an issue, it is not necessary to use consumption
only 75% of the primary copper consumed each year statistics to estimate the end-use (old-scrap) resource
goes to the end-use market, and 25% of it does not. base for the world. We can use, instead, statistics for
This copper has not been dissipated or lost, but has either world primary refined or mine production. Mine
been recirculated and recycled in small amounts and smelter production are used for this paper
every year. because these are the longest, most reliable historical
statistics available. The primary world end-use
McMahon’s calculation procedure provides a resource reservoir also does not include the pool of new scrap
base of end-use copper from which to retrieve old that is recycled and reused every year. Therefore, an
scrapped items. Using the above estimation method, estimated 40% is deducted annually from the world

32
 Figure 12. U.S. Copper Resource for Old Scrap
Pool of Copper Materials In Use, 1959-2007

Million Tons, Copper Content

100

Copper used in end use products

83.1 million tons (cumulative primary refined)

80
 
 
  

60
51.6% recovered as old scrap



and recycled (1864-2007)



40


Old Scrap Recovered 1864-2007
20 42.9 million tons, including exports

59 62 6 5 68 71 7 4 77 80 83 86 8 9 92 95 98 01 0 4 0 7
19 19 19 19 19 19 19 19 19 19 19 19 19 19 20 20 20
Years


USActual Cum Old+Export Scrap

Source: JJolly, Dec. 2007

USActual = Cumulative primary copper consumption increase less annual new scrap generated (1864-2007)..
Old Scrap Cumulative = Cumulative recovery of copper in old scrap returned from end use sector and reused, plus copper in net exports of scrap.

production of primary mined copper to account for (1) copper component and the scrap components can be
processing losses and (2) for recirculating scrap. quantified and compared. These percentage
Because new and home scrap are, by definition, relationships are shown in the diagram of Figure 14
almost 100% recycled and recovered, 25% is for the cumulative (1864 through 2006) resource data.
deducted for recirculating scrap that, in theory, never Even though the available primary copper is
reaches the product reservoir in the year that it is augmented each year by the return of copper from old
generated. Another 15% is deducted from world mine scrapped manufactured items, primary copper is the
and smelter production for the process losses incurred only component added to the resource base. Scrap is,
in conversion to refined copper. Using world mine in essence, derived from the total copper originally
production, the world resource of copper in use, in mined and can not be added as a duplicative
place or buried was calculated to have grown to about constituent to an end-use resource base.
309 million tons of copper (Figure 11) by 2007.
There seems to be some confusion about the
The resource of available copper in end-use products representation of new scrap in Figure 14. Material
for the United States may also be estimated by using passed through to final end use cannot include new
actual primary copper and scrap-consumption recirculating scrap that was formed in the process of
statistics reported each year, instead of an estimate manufacture. Using the amount of new scrap reported
for new scrap (Table 6A). A certain amount of new as used , this deduction represents about 25% to 35%
scrap that is generated as home and mill-return scrap each year of the total semifabricates produced. The
in the United States is sold to other companies for use mathematics of this diagram are not meant to indicate
in their semifabricating processes. In 2006, the United that there is a huge reservoir of new scrap waiting to
States derived about 24% of its total copper (primary be used. The cumulative new scrap data shown in
plus scrap) consumption from new purchased scrap Figure 14 represents the amount of new scrap that
(Table 6). See also the data on flow sheet Figure 9 has been recycled (used many times, as much as 4
for gross weight new scrap returned (32%) from times per year) over the period. The annual
copper products produced. percentage relationships will be very similar to the
longer-term cumulative relationships. Equivalent
By using cumulative statistics as a basis for each cumulative data for each item are necessary to
component at a particular point over time, the calculate percentage relationships for all components
percentage relationships between the total primary of cumulative primary copper consumed. End-use

33
 Figure 13. Cumulative Old Scrap Copper
In the United States, 1959-2007

Million Tons, Copper Content

50
Total Old Scrap recovered
42.9 million tons 1/

40
  

  

30





Old Scrap Consumed in U.S.
20
 35 million tons




10

5 9 62 65 68 71 7 4 77 80 83 86 89 92 9 5 98 01 04 07
19 19 19 19 19 19 19 19 19 19 19 19 19 19 20 20 20
Years
Old Scrap Old+Net Exports
Source: JJolly, Dec. 2007
1/ Copper in net scrap exports are added to old scrap consumption.

items produced after deduction of new scrap year between 1906 and 2006, comprising 25% of the
represent the only reservoir from which to finally total copper consumed over the period (see Table 6).
recover old scrap. At the same time, old scrap from obsolete end uses
was recovered at a rate ranging between 6,000 tons
It has been suggested (Thomas Baack, pers. and 620,000 tons per year, 1906 through 2005. This
Communication 2005) that because new scrap has a resulted in a cumulative 42 million tons (51% of the
short life span, the potential exists for the same end-use resource) of old scrap being returned for
physical quantity to be recorded many times as it consumption by 2006 (see Table 6A).
passes through a production stream during a year. It
might therefore be possible that the real physical In the United States, old scrap copper consumed by
quantity of new scrap used each time over and over industry in 2006 was only 148,300 tons. However, by
might be a fraction of the total amount reported as adding net copper in scrap exports (presumed to be
used for the entire year. Hence, if the scrap was all old scrap) to the copper in old scrap consumed by
returned and reused 4 times per year, for example, U.S. industry, about 598,300 tons may have been
the total value for returned new scrap would be 25% recovered as old scrap in the United States in 2006.
of the cumulative amount indicated on diagram Figure Thus, it would appear that about 4 times the amount
14. This would increase the cumulative end use pool of old scrap recovered for use by the U.S. industry,
by about 30.5 million tons and reduce the new scrap also was exported. An increasing amount of old scrap
volume significantly. Application of this applied time collected in the United States has been exported
philosophy is difficult, but may be worthy of since the mid-1970s. This can partially explain the
consideration in future research. consistent decrease over this period in U.S. old scrap
consumption, as illustrated in Figure 13.
Based on reported U.S. annual data, the cumulative
primary refined copper consumed in the United States Old scrap derived from finished products has
since 1864 amounted to 125.8 million tons by 2007 customarily been considered a new resource of
(Table 6A). From this initial mined source, a copper in the year of reuse, as it re-enters the
cumulative 81 million tons (65%) of copper from old manufacturing stream. For the purposes of calculating
and new scrap had been returned for consumption by a current year’s copper consumption, old scrap is a
the industry through 2007. New scrap was recycled at legitimate augmentation to available primary copper.
rates ranging between 4,000 and 970,000 tons per New scrap, on the other hand, is derived from

34
 Figure 14. Relationships of Primary Copper and Old and New Scrap
to U.S. Cumulative Copper Resource Calculations, 1864 through 2007
(metric tons, copper)

New Scrap
Recycled
Old Scrap
46.1 million
recycled --
tons
35 mill tons
(34%)
consumed,
TOTAL 7.9 mill tons
Primary Copper Copper used for Mill
Products & exported
consumed (42.9 million
125.8 mill tons Manufactures
125.8 mill tons tons)
End Use (51%)
Resource
Base
83.1 million
tons Products in
(66%) Use
40.2 million
tons
(49%)

Cumulative End Use

Resource - 83.1 million tons

Note: Each year, the available primary copper is augmented by return of copper in old scrap, which is consumed in
making Refinery and mill products. However, primary copper is the only contribution to the resource base over
time. Scrap, old or New, should not be added in duplication to the primary copper of the end use resource.

manufacturing and processing. It has a short shelf life Calculations related to the cumulative primary copper
and, in theory, recirculates before ever reaching the resource yield an estimate of about 50% of the
end-use market. As McMahon (1965) points out, new resource remains in products in use by 2007. This is
scrap does not, at any time, form a reservoir supply to derived by deducting the cumulative old scrap
supplement new copper. To include recirculating new recycled from the cumulative end-use resource of 83
scrap in consumption estimates each year by adding it million tons. This estimate includes items that are still
to new mined copper (primary), would present a in use, buried or, to a much lesser extent, possibly
double-counting problem, as the same (primary) dissipated. Copper used in chemicals can be
copper goes through the processing chain over and presumed to have been dissipated, but beyond this,
over, never reaching the end-use market. Because of nothing can be definitively quantified as irretrievably
this phenomenon, new scrap also is excluded from lost. Furthermore, it should be noted that these
total copper use annually in order to calculate an calculations do not take into account the growing
estimated primary end-use resource without scrap. amount of copper in end-use products that enter this
This primary end-use resource is the total pool of country as manufactured goods. The contribution of
copper from which to estimate the percentage return these finished-goods imports to the scrapped products
of old scrap, which is derived from the copper used in reported and to the U.S. resource of end-use products
final products. is not easily quantifiable or estimated.

These calculations yield an estimated 83 million tons The rate of old-scrap recovery from the copper end-
of copper accumulated over the period 1864 through use resource increased rapidly prior to 1945, when
2007 as the U.S. resource of copper in manufactured the rate increased in excess of 1% per year, between
products in use (Figure 12). Interestingly, about 52% 1906 and 1938. The recovery of cumulative old scrap
(43 million tons) of this adjusted, theoretical end-use from the total resource was only about 9% by 1914
resource had been recovered and reused as old-scrap but had reached 37% by 1938. The rate of copper in
copper (including exports) through 2007. (Table 6A old-scrap recovery has been increasing by a little less
and Figure 14). Net exports of copper scrap were than 1% per year since 1945 and has hovered around
added to old scrap copper consumed by the U.S. 50% to 54% of the cumulative resource since 1980
industry to achieve a total old scrap yield. (see Table 6A). The annual U.S. contribution to the
copper reservoir of items in use has been increasing

35
at a rate of 1–2 million tons of copper per year since calculation is put into perspective for the United States
1963. in Table 6B of this report and shows a consistent
decrease since the mid-1980’s, and particularly since
The available copper in the end-use resource may 1993. These statistical trends are the result of several
seem large but, as discussed above, the potential rate significant events that have occurred in the United
for retrieval in a uniform and reliable way is limited by States over the past ten years or so.
many factors. Of particular significance is copper’s
long life in many of its end uses. With a recovery life In addition to a decreased amount of scrap
of 25 to 45 years, copper items produced in the 1960s consumed, relative to primary material, the U.S.
and 1970s may only be in the recovery process today. recycling input ratio (RIR), as calculated above, has
It would appear that a sizeable portion of all copper been much influenced by the increased amount of
consumed is still very much in use today. As shown in copper scrap exported since 1994. To calculate a
Figure 14, this would amount to around 50% of the more complete picture of U.S. scrap use and
so-called, end use resource base, as currently recovery, total copper scrap exports must be added to
calculated. the amount of industry consumed scrap reported.
Looking at Table 6B, a striking trend emerges of a
Of all world copper (22 million tons) consumed in decreasing recycling recovery ratio (ROR) from 1992
2006, 30% was from direct melt and refined copper forward to 2004. Between the years 1981 through
scrap sources (Table 2A). Of the total 7.1 million tons 1993, the rate of recovery (ROR) is consistently over
of copper derived from all scrap sources (Tables 2B 61%, reaching as high as 81% in 1986. From 1993
and 2D in 2007, only 2.8 million tons were recovered forward, however, the rate of recovery is shown to
by refining (39%) and might be considered mostly decrease to as low as 46% 1999 and 49.5% in 2002.
from old scrap sources. Copper from refined scrap The rates have been slightly higher since that time,
comprised about 12% of total world copper consumed reaching 61% in 2006. The higher scrap recovery
from all sources. Another 7% of total world copper undoubtedly relates to the higher copper prices since
might also be presumed to be from old direct melt 2004.
scrap, making a total of 19% of copper from old scrap
sources in 2007. The decrease in RIR shown between 1993 and 2002
in Table 6B and rate of recovery (ROR) can be
In a paper issued in 2002, several European analysts explained by at least two factors that affected the U.S.
(Spatari, Bertram et al. 2002) traced the flow of semifabricating industry and scrap recovery trends
copper as it entered and left the European economy over this period. One was the increased availability
during the course of one year. Russia was not and use of primary copper in the production of
included. Across the life cycle, a net total of 1.9 million semifabricates over much of this period. The increase
tons of copper was imported into Europe. About 40% in primary copper consumption was partially
of cathode produced within the flow system was attributable to an increase in wire rod production
directly from old and new scrap. It was estimated that (which consumes less scrap) vis-à-vis a coincidental
about 8 kilograms of copper per person enters the decline in secondary smelting of scrap for use in brass
end-use market each year, only 30% of which is in mill production (which customarily uses more scrap).
alloy form. They also estimate that the waste Secondary smelting and refining of scrap for use in
management system in Europe recycles about 60% of the U.S. industry has been impacted by plant closures
the copper from “waste.” The net addition of copper to and capacity loss over the past ten years (see Table
the end-use “stock” in the copper flow system is about 17B). In addition, primary copper was to become
6 kilograms per person per year. They conclude that more available at a more reasonable price as copper
given the in-service lifetime of the applications of supplies were in world surplus over much of the
copper identified in their flow model, most of the 1990’s. The second factor is the reduction in amount
copper processed during the last few decades still of new scrap produced by the fabricators as
resides in use, mostly in nondissipative uses. processes became more efficient and streamlined.
Because of the surplus supplies and consequent
The International Copper Study Group recently (2004) depressed copper prices, less old scrap also was
completed a study on recycling in Western (ICSG’s returned to the market, as might be expected. This
Copper Flow Model on Recyling Ratios in Europe). resulted in less scrap being made available to the
One consideration outlined in this paper is a statistical U.S. industry for consumption, or for export, over the
methodology for the estimation of a recycling input 1993-2001 period. If the years prior to 1993 can be
ratio (RIR). This recycling input ratio is derived by presumed to be considered more normal, it would
dividing the total scrap consumed in a region by the appear that a more normal rate for the recycling
total semifabricates produced. The RIR illustrates recovery ratio (ROR) in the United States was in
trends in the relative amount of scrap used versus excess of 63%.
primary material in semis production. The RIR

36
During 2005, owing to near term copper market Using this minimal resource calculation to compare
shortages, several articles appeared in the press with the accumulated world consumption figure of 282
regarding a possible high percentage of copper million tons (2004) can give us a minimal percent of
already mined as compared with an estimated total copper already used from an estimated world
copper available in the earth’s crust. Since the Paley resource. The estimated world consumption of 282
Commission Report of 1950, there have been many million tons is only about 6% of the minimal estimated
such discussions and reports attempting to resolve world resource. A more recent (1998) assessment of
the many issues involved with determining the amount U.S. copper resources indicated 550 million tons in
of copper resources available in the world. One such identified and undiscovered resources in the United
report worth remembering is that appearing in U. S. States, more than double the previous estimate
Geological Survey Professional Paper 820, pp 21-25. (USGS Circular 1178, 2000).
This 1973 article, entitled “Crustal Abundance of
Elements, and Mineral Reserves and Resources”, by A word of caution -- It is obvious that these
R. L. Erickson, proposes a methodology for estimating reserve/resource numbers are very fluid and change
the recoverable amounts of several metals in the with time. One must read and understand the
earth’s crust. The potential recoverable resource for definitions for reserves, reserve-base and resources
6
most elements should approach R=2.45AX 10 , to understand the reasons underlying the near
where A is the abundance expressed in grams per doubling of reserves between 1970 and 2004.
metric ton, or parts per million and R is the resource Absolute amounts are impossible to quantify, thus a
expressed in metric tons. Those metals whose definitive statement about the percentage copper
reserves most closely approach the calculated already used in the world, compared with that possibly
potential recoverable resource are the metals that available is at best, wildly speculative. Statements
have been most diligently sought, such as copper. made about running out of the potential for copper ore
The formula calculates the minimum total resource are irresponsible and generally are made for various
available, largely because it relates to currently political and notoriety reasons.
recoverable resources and does not include resources
whose feasibility of economic recovery is not In testimony before the Committee on Resources
established. Subcommittee on Energy and Mineral Resources in
the U.S. House of Representatives (May18, 2006), a
Using this formula (called the McKelvey formula) spokesman for the U.S. Geological Survey reported
assumes (1) the Bureau of Mines (now USGS) that a current study estimated that about 1.1 billion
estimate for world reserves are the correct order of tons of copper will be needed between 2000 and 2020
magnitude, (2) that McKelvey’s relation of reserves to at current rates of consumption. This will necessitate
crustal abundance is valid, and (3) that trace elements additional producing reserves equivalent to three
are log-normally distributed in the earth’s crust. Using times the amount of copper as is contained in the 5
the world copper reserves reported then by the largest known deposits. Although some of this
Bureau of Mines, Erickson estimated that for 1970 the material exists in discovered deposits, much will need
reported reserves of 200 million tons resulted in a to come from yet undiscovered deposits. The need for
recoverable resource potential of 2.12 billion tons of active exploration and mine development continues.
copper. This contrasts with reported world copper
reserves (2005 Mineral Commodity Summary, USGS)
for 2004 of 470 million metric tons of copper (and, a
reserve-base of 940 million tons). Using this latest
data with the Mckelvey formula would yield about 5
billion tons of potential recoverable copper, more than
double the amount estimated for 1970.

37
CHAPTER 3: can be used to further ensure that metallic choppings
are free of plastic. Finding a use for the “fluff” or
Overview of Scrap Preparation, discarded plastic materials also is not always easy.
Melting and Processing Some manufacturers of molded parts and auto and
truck parts makers have been able to use certain
types, but getting a pure mix of plastics is sometimes
Scrap Preparation difficult.

All scrap used must be prepared and analyzed prior In recent years, owing to the vast labor and copper
to processing to alter its shape and size and/or its price differences between China and India with North
purity. This can sometimes add significant cost to its American or Western Europe scrap processors, some
use. Scrap preparation may be done by manual, U.S. shredder operators were forced to rethink their
mechanical, pyrometallurgical or hydrometallurgical downstream systems to determine whether or not it
methods. Manual separation and cutting of large was worth the operating costs to purify metals to such
pieces of scrapped items is very necessary, as is an an extent. Many scrap processors were accustomed
accurate analysis of the material. Large, solid items to using automation to meet strict chemistry
are reduced in size by diamond saws, shearing requirements for copper shipments, but exports to
machines, pneumatic cutters, or manually by a China and the Far East changed this with the
sledgehammer. Mechanical methods include sorting, willingness of foreign importers to buy mixed or
stripping, shredding, and magnetic and air separation. crudely sorted loads of metal. It has steered some
Because scrap is a bulky material, the customary recyclers to do a lot less sorting of loose brass,
practice is to bale light scrap and cut heavy scrap to copper and aluminum scrap with overseas customers
size so that it can be handled. The scrap may be able to do this sorting much more affordably.
further compressed by hydraulic press into briquettes,
bales, bundles or hockey pucks. Brittle, springy During much of 2003, U.S. scrap recyclers of wire and
turnings are crushed in hammer mills or ball mills to cable were worried about their future. At the time,
reduce bulk for easier handling. Slags, drosses, brokers representing consumers in China were
skimmings, foundry ashes, spills, and sweepings may making generous offers and getting access to scrap
be ground to liberate prills or other metallics from the that had previously gone to the choppers. Fortunately,
nonmetallics so that metallic fraction can be recovered trading patterns shifted somewhat in 2004. Customs,
by gravity separation or other physical means. They trade and environmental regulations in China
may also be set aside in special areas to be drained combined to slow down the buying pace of Chinese
of oil before further processing. Pyrometallurgical brokers, abeit temporarily. U.S. wire processors
preparation may include sweating, burning insulation began to re-establish trading ties with customers
from copper wire (not recommended, and may be (Recycling Today, October 2004). The renewed
banned) and kiln drying to volatilize oil and other business allowed some processors in the United
organic compounds. Cartridge shell scrap may also States to begin upgrading their systems. The objective
be heated in a furnace to pop the live shells. was to remain competitive while recovering as much
metal as possible, but keeping their costs down.
An important copper recycling material is cable scrap. Recent gains in volume allowed upgrade to larger
At one time, burning of cable to remove the plastic shredding units and the conveying systems to match.
parts was acceptable practice, but this is no longer The cost of blade replacement was also closely
always possible or desirable. Thus, mechanical monitored.
dismantling of the cables is common practice through
cutting, granulating and use of various metal In 2002, it was reported that lower grades of wire
separation techniques to separate the plastics and increasingly have been heading overseas for
fluff from the metal. Most wire is chopped into pieces processing (Recycling Today, Feb. 2002). This may
smaller than 0.5 inch to assure liberation of wire from partially account for the increasing gap between what
insulation so that air tabling can then make a some countries report as exported (see Table 3) what
separation. Another mechanical device strips other countries , particularly China, report as imported
insulation from long lengths of cable. Over time, wire (see Table 4). There is obviously a difference in
choppers have been able to upgrade insulated wire to reporting scrap values, which seems to be worsening
No. 1 grade instead of No. 2, which was generated by every year.
burning.
In developing countries, plastics are disposed of not
After cable material travels through shredders and only through landfilling but also by open burning of the
granulators, a variety of equipment – gravity or air coated wire. While copper and aluminum have resale
density tables, washing systems, fluidized bed units – value to smelters, the plastic coating is often
disposed, or burned away. Recycling Today estimates

38
that some 700 controlled-atmosphere furnaces have nations, such as China. Beryllium copper clips
been sold worldwide to scrap recyclers who use them gleaned from these electronics are sorted and sent
to burn off plastic coating. Scrubbers are used with back to beryllium copper producers in Ohio and
these furnaces to remove the hydrochloric acid Pennsylvania. Handling these materials must be done
generated when burning PVC. Open burning offers no carefully, since any hazardous materials from
such protection. landfilled electronics can leach into the soil, and, when
burned, toxins can be released into the air.
Flotation may be used for copper slags to concentrate
and recover copper when the slag treated contains Some companies recycle copper by
more than 10% copper. The slag is ground and hydrometallurgical processing of weak or spent
combined with water and flotation chemicals. The copper plating solutions and sludge generated by
additives help the copper to float for removal and wastewater treatment of copper plating operations.
concentration and to prepare it for further processing. The product is sent to a smelter for further processing.

In 1974, H. Fukubayashi (USBM RI 7880, 1974)

estimated that flue dust collected from secondary Laboratory Testing
brass furnaces averaged about 2 tons per day per
operating brass furnace. The material is ordinarily too Several standard methods of testing scrap materials,
light and fluffy for easy handling and, thus, is shipped ingots and other alloy products are used. Methods
in containers, such as barrels, to the zinc smelters for such as chemical analysis, optical emission
metal recovery. Pelletization of the zinc dusts reduces spectroscopy, x-ray fluorescence, atomic absorption
the volume for shipping and facilitates handling. Some analysis, inductively coupled plasma-emission
companies ship up to 2,000 pounds of zinc dusts in spectrometry analysis and various types of
large plastic bags (Supersaks). mechanical testing are used. Details for conducting
wet chemical analysis on copper-based alloys are
When circuit boards used by the printed wire board given in several ASTM standards (E 478, E 54, E 75,
industry are manufactured, the bonded copper foil that E 88). The wet chemical methods are slow and make
is applied to the fiberglass sheets is trimmed by it difficult to obtain results for production heats until
shearing off the rough edges. This copper-clad trim is well after the metal has been cast, limiting their value
shipped to some hydrometallurgical firms for as a process control tool. More commonly, chemical
processing to produce copper chemicals. During the methods are used for analyzing the composition of
production of printed wire circuit boards, a cupric raw materials (ingot and scrap) before being melted.
ammonium chloride etchant is used for removal of The mechanical tests usually associated with copper-
copper metal from the unprotected parts of the based foundry alloys are those for hardness, tensile
boards. Copper increases in the etching solution as and impact-strength properties, following various
the process proceeds. The spent etchant is shipped to ASTM standards. Radiographic inspection of metallic
a hydrometallurgical processor for removal of the objects is a means of observing internal defects
copper and regeneration of the etchant. Another nondestructively by using either x-rays or gamma
etchant is cupric chloride. Spent cupric chloride rays.
etchant contains about 1.2 pounds of copper per
gallon. This metal is also recovered, but the etchant is Occasionally, a radioactive check must be made on
converted to ammonia chloride, which is returned to materials received for processing. Copper scrap from
the circuit board industry. atomic power plants is particularly suspect. While the
radioactive elements can be separated from the
Some large U.S. companies have shredders that can copper metal produced, the slags may become
process electronic materials to allow for metal contaminated and radioactive.
recovery. Canada is a large export market for circuit
boards that can be handled by shredder and smelter.
According to Recycling Today (Feb. 2002), a Energy Use
Midwestern recycler dismantles computers and other
electronic products by hand and sends the circuit Recycling provides benefits such as energy savings.
boards to smelters (presumably in Canada), which Of the commonly used metals, copper has one of the
have associated shredders. Because the company lowest energy intensities for production. The energy
charges a per-pound fee to recycle electronics, the intensity for recycling of copper varies by the purity of
dismantling is financially viable. Many of the the scrap. Clean scrap, which requires only remelting,
computers handled are reused instead of dismantled. requires only about 1 MWh/t. Scrap that requires
There is a strong demand for the reuse of Pentium electrolytic refining requires about 6 MWh/t, and that
133s, but anything less is likely being purchased by which must be purified by re-smelting requires about
dealers who send the computers to third world 14 MWh/t.

39
Because many applications for copper, particularly comprised 94% of all copper from U.S. scrap
alloys, use scrap rather than virgin metal, the energy consumed in 2006(Tables 2C and 2D). The scrap
intensity of that metal is a function of how much scrap remainder is reprocessed by either smelting or
is used. For example, in a copper and brass refining or by leaching and electrowinning to form a
automotive radiator, which typically uses 40% scrap, pure copper product. Fire refining in a reverberatory or
mainly for brass in tubes and header plates, the other furnace may be sufficient for the better grades.
energy intensity is 20 MWh/t, not the 30 MWh/t of
newly produced copper. The fire-refining process uses oxidation, fluxing and
reduction to produce refined ingot, wire bar, slab or
Scrap Preparation. Chopping of copper wire requires billet. For higher grades of refined cathode, however,
about 1.75 million Btu (USBM, IC 8781, 1978) per ton the poorer grades of scrap must be first smelted with
of prepared scrap; 1.05 million Btu of which represents various fluxes, poled to remove oxygen, and then cast
process energy, 0.40 million Btu represents pollution into anode form for further processing to cathode in an
control energy, and 0.3 million Btu is for space heating. electrolytic refinery. By-products, such as tin and
By comparison, incineration of the covered wire precious metals, may be retrieved during the
requires 1.67 million Btu, most of which is consumed in preliminary procedures of smelting or, during refining,
the afterburner. If the insulation contains PVC, a from tank house sludges. Other impurities, such as
serious air pollution problem arises, requiring the use of iron, lead, arsenic and antimony may be removed
wet scrubbers and the treatment of the effluent. The from the slag by fluxing. Reverberatory or electric
electric energy required for compressing low-density rotary melting furnaces are used for casting various
scrap into balers is less than 0.05 million Btu per ton. copper forms, such as slabs, cakes, billets or ingots.
For briquetting, the electric energy requirement is on Asarco shaft furnaces may be used with holding
the order of 0.10 million Btu per ton. furnaces, in conjunction with continuous casting
systems.
Melting Scrap. Reverb melting of No. 1 copper scrap
requires about 3.81 million Btu per ton of refined Processing complex copper-containing materials,
copper shapes poured, such as billets and cakes. Of such as drosses, flue dust, catalysts, collector dust,
this, about 95% is process energy; the remainder slimes from electroplating wastewater, and metal-rich
represents pollution control and space heating energy. slags from converter and furnace processes requires
Recycling of No. 2 scrap requires process energy of versatile production processes. Low-grade, copper-
15.71 million Btu per ton of poured copper wire bar. bearing scrap, such as copper-containing skimmings,
Air pollution control energy accounts for 0.21 million grindings, ashes, iron-containing brasses and copper
Btu per ton of wire bar, and space heating accounts residues are usually smelted in a cupola or blast
for an additional 1.35 million Btu per ton. The total of furnace to produce black copper. Black copper is then
these components amounts to 17.27 million Btu per converted to blister copper in a converter and, then, is
ton of copper wire bar produced from No. 2 scrap. fire-refined or electrorefined, much as in the primary
copper industry.
Process energy required for recycling brass and
bronze scrap to ingot (85:5:5:5 red brass) is about Most metal processing plants have built-in water
5.86 million Btu per ton of alloy produced. Air pollution recirculation systems and pickling solutions in which
control energy accounts for 0.91 million Btu, and some of the metal content is recaptured and reused.
space heating accounts for 0.32 million Btu, making a Many of these wastes also must be treated for metal
total energy requirement of 7.09 million Btu per ton of recovery. In general, a combination of various
red brass alloy produced. The energy analyses for hydrometallurgical techniques such as precipitation,
other alloys are not significantly different. cementation, ion exchange, solvent extraction,
reverse osmosis, gaseous reduction and electrolysis
Process energy for processing low-grade, copper- are used. Cementation has been successfully
bearing scrap (25% to 35% copper) in a reverberatory employed to recover copper from waste effluents.
or cupola requires 39.70 million Btu per ton of product. Solvent extraction and ion exchange are highly
Total energy required is 42.42 million Btu per ton of selective methods for separation of copper from other
product, including 1.37 million Btu for pollution control common metals in solution. Mechanical and thermal
energy and 1.35 million Btu for space heating (USBM, dismantling, and more recently, leaching and solvent
1978). extraction and electrowinning procedures have proved
effective in treatment of certain types of electronic
scrap and copper-coated steel wire. Electrowinning
Scrap Melting and Processing recovery is also used for waste processing fluids and
sludges that contain copper and other metals. A low-
Most purchased new scrap is simply melted at ingot grade copper cathode, as well as copper chemicals
makers and brass mills. Copper from direct melt scrap such as copper sulfates, oxides and hydroxides,

40
copper precipitates and by-product metals can be furnace time, crucibles or refractories that are inert to
produced through this method. the melt, and melt covers or fluxes. Lower
temperatures result in less dross through lower
Melt Control. The term melt control refers to the chemical reaction rates. Clay graphite crucibles
control for furnace and atmosphere conditions during provide carbon in the crucible that will react with the
processing of molten metal. Variables affecting melt atmosphere, resulting in less dross. Melt covers, such
quality include the following: (1) Furnace selection; (2) as charcoal, carbon and fluxes, show mixed results
Fluidity (Higher pouring temperatures make chemistry but also can be effective in reducing the amount of
and gas control more difficult.); (3) Mold materials (All dross formed. One company reported an 80%
materials can produce gas, and mold gas coupled reduction in dross and ash formation through the use
with gas derived from melting can result in “gassy of synthetic graphite instead of charcoal as a melt
castings”); (4) Gating (Improper gating can result in cover.
gas pickup and porous castings.); (5) Solidification
and shrinkage; and, (6) Mechanical properties (Input Melt Covers (Fluxes). Fluxing is an essential part of
materials are commercial-purity raw materials, scrap, both melting and refining. The basic functions of
secondary ingot, returns, and late additions. How fluxes are essentially the same, whether used in
much of each is used is dependent upon availability, reverberatory, rotary or crucible furnaces. Two
cost and the casting quality required). Some general types of fluxes used for melting and refining
companies use a computerized system to determine scrap copper are: (1) Nonmetallic fluxes and (2)
the heat characteristics, cost and most efficient Fluxing alloys. Nonmetallic fluxes may be solid, liquid,
method of mixing the melt, including the detailed gaseous or mixtures of these. Some are used for
procedure to be followed in forming it. This helps to protecting the surface of a melt from the atmosphere,
simplify the procedure to be followed for a particular while others refine by mechanical or chemical
alloy. Often, three or more scrap types are required reaction.
for a given melt.
Nonmetallic fluxes include materials such as sodium
Commercial-purity raw materials are seldom justified chloride, charcoal, borax, anhydrous rasorite,
on cost, except possibly for new alloy development. slacklime, glass, nitrogen, oxygen and various
Other pure metal scrap, such as zinc strip, may also combinations of these. Sodium chloride may be used
be used for adding metal to the melt. Some elements, as a cover and as a fluid medium for separating
such as silicon in the silicon bronzes and iron in the metallic and nonmetallic materials in heterogeneous
aluminum bronzes, do not readily go into solution in melts. Charcoal covers are used to add heat to the
copper and, so, are often purchased as already surface and provide a reducing atmosphere. Borax,
alloyed ingot. These additive alloys are called master slacklime and glass are added in various
alloys. Master alloys contain 10% to 15% of the combinations to protect the metal surface and reduce
desired metal required. Most foundries to do not volatilization of the melt. Anhydrous rasorite is a
compound their own alloys from raw materials. The sodium borate flux used in the secondary copper
practice of using an all-scrap charge creates the risk industry. This flux has a great affinity for metal oxides
of possible pickup of detrimental elements. On the and siliceous materials and is used primarily to
other hand, scrap, such as pure copper bus bar, wire scavenge oxides and to provide a protective cover for
or piping, provides an excellent charge of known molten scrap brass and bronze. Borax is also used to
characteristics. Another example of scrap use is the aid the release of ingots from their molds. Caustic
melting of soldered brass automotive radiator cores soda has been used for the removal of iron and
for plumbing alloy castings, because of the known aluminum from some alloys. Gaseous fluxes are
lead content. usually introduced into the melt through a pipe
inserted below the surface. Small bubbles of inert gas
Drosses and Dross Formation. The most common adhere to particles providing buoyancy, which raises
causes of melt losses are dross formation due to them to the surface where they can be removed with
reaction with the atmosphere, refractory material, or the slag.
ladle material, and losses owing to vaporization of
low-boiling point elements. Even if secondary ingot Metallic fluxes are either pure metals or alloys that
charges are well within a chemical specification range, can be introduced to the melt to produce a refining
melt losses may result in scrap castings. Much of the action. A metal fluxing agent used for copper-base
dross in copper-base alloy melts (Casting Copper- alloys would also be alloyed with copper as a base
Base Alloys, 1984) is due to reaction between the metal. Fluxing alloys are usually classified according
metal and the atmosphere, since it is usually not to their functions. They are known variously as
possible to exclude the atmosphere. Several deoxidizers, degasifiers, densifiers, stabilizers and
techniques may be used to minimize dross formation. fluidizers. Many provide two or more of these
These include the use of lower temperatures, shorter functions simultaneously. Some melters may use the

41
fluxing alloys as master alloys to produce others that and chromium are strong deoxidizers, no
are not commercially available. Phosphor-copper, for deoxidization treatment is required for melting these
example, contains 10% to 15% phosphorus alloy and alloys. However, deoxidization is required for melting
is used for deoxidizing. In some cases, the flux alloy is pure copper. In forming high-conductivity copper, a
added so that the excess phosphorus will alloy with high oxygen content is induced to the melt to limit the
the melt as one of the desired constituents. In this amount of hydrogen and to oxidize impurities that may
case, the alloy is used as a deoxidizer and a be deleterious to conductivity. The melt is then
hardener. There are many other fluxing alloys such as deoxidized using calcium boride or one of the various
the binaries of silicon, manganese, magnesium, deoxidants available commercially.
lithium and cadmium.
Cut cathode squares (an alternative primary raw
Oxidizing melt covers (copper oxide, silicate-borate material) contain no oxygen; hence, they may contain
mixtures) can be used to remove hydrogen, or considerable hydrogen, and strong oxidation will be
maintain it at low levels, and to consolidate drosses needed to remove it. In-process scrap should contain
and oxides for ease of removal. Neutral melt covers neither oxygen nor hydrogen but may contain residual
(glass, dry silica sand) form a mechanical barrier deoxidants.
between the melt and the furnace atmosphere. This
can reduce exposure to hydrogen sources, but may Vapor Losses. The techniques used for dross
also prevent oxygen absorption; it is generally not minimization will also reduce vapor losses. The most
reliable for gas control, but it is advantageous for notable element loss in molten copper (brass) alloys
dross removal and reduction of vaporization losses. takes place with zinc, which is usually replaced in the
melt just prior to pouring. Elements such as lead and
Reducing melt covers (charcoal, graphite) prevent beryllium may also be associated in the processing of
excessive oxidation losses but may be a source of some copper alloys.
hydrogen, if they contain moisture or hydrocarbon
additives. If used in excess, they may prohibit oxygen Particulate Matter and Fugitive Emissions.
absorption from the melt atmosphere, thereby Secondary smelting and melting processes release
allowing hydrogen pickup. Reducing melt covers are some particulate matter into the air stream used to
useful in retaining a low oxygen level in the metal after oxidize undesirable elements in scrap. Since scrap
deoxidization and prior to pouring. does not contain considerable sulfur, arsenic or other
volatile elemental combinations found in natural ore
Fluxes or slag covers are generally unnecessary minerals, these are not of great concern here. The
when melting copper and beryllium copper alloys. A principal materials of concern are those derived from
layer of dry charcoal or granular graphite may be used burning plastic coating materials and electronic
to cover molten copper. In melting chromium copper, boards, when a smelting technique is used for these
a flux cover of lead-free glass or liquid salt is materials. New hydrometallurgical procedures have
recommended to minimize oxidation of chromium. been developed, however, that have been shown to
be efficient in removing the precious metals, copper
Fluxing materials used in a typical blast furnace and other metals from these materials. No fugitive air
include limestone, millscale, and metallic iron. The emissions are involved. Another group of elements of
resulting slag from a 60- to 70- ton-per-day blast concern is that of more volatile metals partially
furnace (Spendlove, 1961) with charge materials released during the melting of some copper alloys.
containing 10–11% coke, will have the following These include zinc, mercury, lead and cadmium.
approximate composition: FeO (29%), CaO (19%), Numerous mechanisms have been developed to keep
SiO2 (39%), Zn (10%), Cu (0.8%) and Sn (0.7%). these emissions to a minimum as well as to capture
most of the emitted metals through the use of
Use of Deoxidizers. Phosphor copper is often used emissions scrubbing systems. Both wet scrubbing and
in deoxidization of copper and copper alloy melts such electrostatic precipitators are used. Particulate
as in making copper tube and copper-tin-lead-zinc emissions associated with metal processing can be
alloys (red brasses and tin bronzes). The principal collected in mechanisms called baghouses. Products
cause of high residual phosphorus is over- recovered from baghouse dusts are generally
deoxidization. This usually occurs for one of two valuable materials that can be sold for further
reasons: (1) Porosity problems are misjudged to be processing or for direct use in certain applications.
the result of insufficient deoxidization, or (2) Extra However, because these materials sometimes contain
phosphorus is added to impart greater fluidity to the certain metals currently classified as hazardous air
metal to avoid misruns in thin castings, or when pollutants (HAPs), as defined in Title III of the 1990
pouring cold metal. Over-deoxidization will result in Clean Air Act Amendments, they are shipped and sold
gassy castings and will negate efforts to maintain low as hazardous materials.
hydrogen levels during melting. Because beryllium

42
The current trend has been to eliminate the burning of used in the anode furnace of primary copper
covered, insulated wire and to use mechanical means production. Scrap is melted and partially fire refined.
to prepare the copper wire for further processing. Wire After the melt is oxidized to saturation, a poling step is
burning generates large amounts of particulate matter, carried out until the oxygen content is around 0.2%.
primarily composed of partially combusted organic The molten copper is then cast on a molding wheel,
compounds. Direct-flame incinerators, called either into anodes for further electrolytic refining or
afterburners, can effectively control these emissions. into wire bar or ingot for use by foundries and brass
An efficiency of 90% or more can be achieved if the mills. When anodes are refined, the tank house
afterburner combustion temperatures are maintained sludges are sources of valuable by-products such as
above 1000 C (1800 F). If the insulation contains precious metals.
chlorinated organics, such as polyvinyl chloride,
hydrogen chloride gas will be generated. Hydrogen To process low-grade copper scrap, secondary
chloride is not controlled by the afterburner and is smelters commonly use a combination of cupola,
emitted to the atmosphere. In eliminating the burning blast, reverberatory or rotary furnaces that are either
of insulated wire, however, a by-product called fluff is gas or electrically fired. A flux is commonly added to
generated. The industry has been working in retrieve impurities in the earlier stages of the process,
conjunction with firms such as Goodyear Rubber to and a slag product is also produced in addition to the
find new uses for this material. Generally, however, it high-copper melt. The upgraded copper melt is
is baled and sent to a hazardous materials dump charged to a converter where the product is oxidized
because of its lead content, which was used in to remove unwanted gases and the purity is increased
plastics to prevent exposure breakdown while in use. to around 90%. It’s then moved to a fire-refining
furnace where the product is further upgraded to
The EPA reported emission factor averages and around 99% copper and is poled with either gas or
ranges for six different types of furnaces are shown in wood to remove the residual oxygen.
Table 19, the data for which was derived from
unpublished documents of the New Jersey Arc Furnaces. Once popular, arc furnaces are not
Department of Environmental Protection; New York used as much in copper-alloy ingot makers and
Department of Air Resources; Wayne County, foundries today. Whether direct-arc, indirect-arc or
Michigan, Department of Health; the State of Ohio submerged-arc, these furnaces melt within a closed
EPA, the City of Chicago Department of chamber. The material is heated either directly by an
Environmental Control; the City of Cleveland electric arc between an electrode and the work or
Department of Public Health and Welfare; and the indirectly by an arc between two electrodes adjacent
South Coast Air Quality Management District in Los to the material (ASM Metals Handbook). The intense
Angeles, California. heat of the arc causes combustion of the graphite
electrodes to occur by reaction with any oxygen
present in the furnace atmosphere. The remaining
Furnaces atmosphere is nitrogen, carbon monoxide and any
residual moisture from incoming air. Suppressing
The kind of raw material that can be used depends hydrogen absorption by excess air has the
upon the furnace in use at a plant. Fire refining and disadvantage of greatly increasing the rate of
smelting require large furnaces or cupolas that are electrode consumption. Sealing off the tap hole with
distinctly different from that used for direct melt of refractory cement also minimizes the flow of air into
scrap. Few ingot makers or brass mills and no the furnace, but it depends upon keeping atmospheric
foundries maintain furnaces that are sufficient for moisture out. Flushing the heat with dry nitrogen or an
large-scale fire refining or smelting. These types of inert gas can reduce hydrogen absorption, if
furnaces generally are left to those firms that necessary. The submerged-electric-arc furnace is
specialize in secondary smelting and refining. The used for extracting metal components from reduced
stationary reverberatory is the most practicable scrap pellets by Inmetco, according to its Web site,
furnace for large tonnage, but the rotary furnace is where it claims to be the only secondary submerged-
more flexible. Tilting and stationary crucible furnaces, arc smelting furnace in North America dedicated to
either gas or electric, are used for making small melts the high-temperature metal recovery of nickel,
of special alloys. Electric induction furnaces are chromium and iron.
popular at ingot plants and foundries where special
alloys are made. These furnaces also are used for
melting scrap and other materials in casting billet and
other shapes. ASARCO Furnaces. Named after the American
Smelting and Refining Company, these furnaces are
No. 1 and No. 2 scrap can be melted in a reverb or commonly used for melting pure copper cathodes and
rotary furnace for fire refining, similar to the process clean scrap. The product is tough-pitch copper, which

43
is normally fed to wire-rod casting machines. They with little or no reduction of oxidized materials, it is
were first operated in the late 1950s and have since called a cupola. The typical secondary blast furnace is
been built in a range of sizes. They are shaft furnaces a top-charged, bottom-tapped shaft furnace that is
shaped internally like an inverted cone, about one-half heated by coke burning in a blast of air introduced
as wide at the bottom as at the top. By adjusting the through tuyeres placed symmetrically around the
fuel-to-air mixture, the atmosphere is kept slightly bottom of the shaft. The upper section of the shaft is
reducing. Fuels include natural gas, propane, butane cylindrical, but the lower section (the bosh) is an
and naphtha. Energy consumption is 1 million Kcal inverted, truncated, tapering cone. A crucible is placed
per ton of cathode. below the bosh to collect molten metal and slag
produced in the smelting zone above. Refractories
Crucible Furnaces. A fairly large tonnage of used in the furnace are usually fire-clay brick from top
secondary copper products is produced in crucible to bottom. The crucible is lined with magnesite or
furnaces. These furnaces are fuel-fired with natural chrome brick.
gas, fuel oil, propane or combinations of these. These
fuels are all hydrocarbons. As a result, their The scrap is heated as it descends through hot rising
combustion causes the formation of large quantities of gases, becoming liquid when it reaches the smelting
water vapor. The water vaporizes if part of the visible zone. Brass and copper may actually melt above the
flame comes into contact with the molten metal before normal smelting zone. Limestone, silica and iron oxide
it is exhausted from the furnace. Crucible furnaces are fuse in the smelting zone and form a molten slag,
used for melting clean, well-segregated scrap – which mixes with the metals in the gas turbulence.
mostly in foundries. Nonmetallic fluxes are used for a The gases rising through the shaft are composed of
protective covering, but alloy fluxes may be added as CO, CO2 and nitrogen. The amount of carbon dioxide
a refining agent and as a means of introducing some increases at higher elevations in the shaft; the coke-
constituents into the melt. to-air ratio is adjusted to provide a reducing
atmosphere. Oxides of the base metals either dissolve
The most common cause of porous copper-alloy in the slag or fume off; many are reduced and
castings is the reaction of the water vapor with the dissolved in the copper. The black-copper product of
molten metal allowing dangerously high amounts of the blast furnace may contain zinc, lead, tin, bismuth,
hydrogen to be formed and dissolved by the melt. Use antimony, iron, silver, nickel or other metals contained
of a cover material on the surface of the molten bath in the scrap. Many of these are later fumed off and
has been used to avoid or prevent hydrogen recovered as baghouse dust.
contamination in fuel-fired furnaces. The use of
glassy, slag-like covers can be relatively effective in Both slag and metal are usually tapped through a
protecting the melt, but there are disadvantages. Such launder into a reverberatory where they are held in a
covers can prevent oxygen in the furnace from quiescent state to allow more complete separation of
reacting with the bath. The British, reportedly, have metal and slag. The metal product produced in the
been known to add oxidizing materials, such as blast furnace will vary widely depending upon the
cuprous oxide, to the slag cover to overcome this materials charged. The range of composition will be
disadvantage. At best, however, covers can be a 75% to 88% copper, 1.5% tin, 1.5% lead, 0.1% to
potential source of inclusions in castings, and their 0.7% antimony, 0.5% to 1.5% iron, 4% to 10% zinc,
use shortens the life of furnace refractories and and 0.5% to 1.25% sulfur. The calcium-iron-silica slag
reduces the thermal efficiency during melting. may also contain up to 1.5% copper.

Scrap is usually melted in crucibles by the puddling Reverberatory Furnaces. A reverberatory furnace is
method – melting enough scrap to make a liquid a box-like, refractory-lined structure designed to heat
puddle, then forcing new scrap below the surface to the charge by both conduction and radiation. The
become part of the molten body. Crucible furnaces furnace is usually lined with magnesite, or chrome-
may be either stationary or tilting, the latter being the magnesite bricks, fused magnesite bottoms, and
most preferred. A ceramic-type of material (dry- suspended magnesite brick roofs. Secondary smelter
vibration, low-moisture castable lining) is usually used reverberatories may be as large as 100 tons per day
to line the furnace in a manner not unlike molding or more. Charge materials must contain a minimum of
cement. 40% copper in order to prevent excess slag
accumulation, which reacts with the refractories and
Blast Furnace, Cupola. The function of a blast shortens the furnace lining life. Scrap is charged at
furnace is the reduction of copper compounds and the regular intervals until the furnace is filled. Melting is
formation of copper matte and slag. The blast furnace more efficient, if light scrap is densified by bailing or
is used in secondary smelters for smelting low-grade briquetting. Oxidation and volatilization losses are
copper and brass scraps, refinery slags, drosses and usually kept to a minimum by rapid melting in a
skimmings. When used primarily for melting scrap, slightly oxidizing atmosphere with a fairly fluid slag

44
cover. A few of these furnaces are still in operation as furnace is compact and can be completely enclosed to
fire-refining operations associated with copper tube prevent any stray emissions.
mills in the United States. The reverberatory furnace
used for processing primary copper and scrap at Low-frequency Induction Furnaces. Brass mills
primary copper operations has disappeared. Primary may use low-frequency induction furnaces to melt
copper producers currently use flash-furnace copper, copper-alloy scrap, runaround (home) scrap,
technology for smelting ores and concentrates. Flash and significant amounts of primary copper and
furnaces, operating with the exothermic heat of sulfur alloying elements such as slab zinc. Melting rates with
oxidation, do not require much scrap except for induction furnaces can be high, but capacity is
cooling the melt. This has resulted in a significant typically limited to a maximum of 5 metric tons. Energy
reduction of low-grade copper scrap consumption by costs for melting are usually higher due to the use of
the primary producers. electrical power, but this may be compensated by the
fact that no combustion gases are generated and no
Converters. Scrap may also be added to a primary gas handling system may be needed. The heating
copper converter as a convenient way to keep the equipment is more complex than standard gas
melt from exceeding the proper temperature. These burners. Induction furnaces produce little metal
vessels are used for converting primary copper matte, oxidation and have high metal recovery rates.
an impure mixture of iron and copper sulfides, into However, they require relatively clean scrap, since
blister copper by oxidizing the sulfides. The sulfur contaminants tend to be entrained or entrapped in the
dioxide gas is expelled with other furnace gases, and recirculating molten metal pool.
the iron oxide combines with a siliceous flux to form
an iron-silicate slag, which is poured off. A converting Electric induction furnaces are often used for melting
vessel is also used for making blister from black scrap and other metal materials in casting billet and
copper derived from scrap materials, as described other shapes.
above.

Rotary Furnaces. Top-blown, rotary converters (e.g. Sweating

Kaldo or TBRC furnaces) are sometimes used to
smelt and refine copper-bearing materials. These Scrap as journal bearings, lead-sheathed cable,
furnaces are more flexible than reverbs, but the radiators and mixed auto shreddings can be sweated
capacities are limited in size to about 50 short tons to remove babbitt, lead and solder as valuable by-
per day of nonferrous metals. They can be operated in products, which would otherwise contaminate a melt.
batch or semicontinuous modes. Various feed Both reverberatory and muffle furnaces are used for
materials can be used, such as primary and this purpose. The simplest furnace for sweating is the
secondary base metals and anode slimes. Fine feed conventional sloping-hearth-fired furnace (Spendlove,
materials can be fed directly into the furnace without IC 8002, 1961). The charge materials are placed at
any pre-treatment, such as briquetting or screening. the highest point on the hearth. Low-melting
The barrel rotation ensures good mixing of flux and constituents liquefy and flow to the low end of the
scrap. The thermal efficiency is good owing to direct hearth and out of the furnace into a collecting pot. The
heating of the barrel walls by the burners, followed by sweated babbitt, lead or solder may be used to make
direct conduction of the hot refractory wall to the white-metal alloys. Small-sized scrap can be sweated
charge as it rotates. Some believe that it has an efficiently in a rotary kiln, with scrap charged
advantage over stationary furnaces for melting loose continuously at the elevated end of the kiln.
or bailed light scrap. The rotary furnace is a cylindrical
steel shell with insulating material placed inside next Because some soldered items are difficult to sweat
to the shell. Magnesite or chrome-magnesite brick is when the solder remains in folds and seams, even
used for lining. A cushion of grain magnesite usually when melted, other furnaces have been developed to
backs the brick lining. Linings may last 100 or more counteract this problem. One is a reverberatory
heats, and the capacity of the furnace may increase furnace with a shaking grate of steel rails about the
owing to the erosion of the lining by abrasion and size of the furnace floor. The scrap is shaken to
reaction with the slag. Heat losses also increase remove the liquid solders from the scrap. The molten
proportionately. Flux comprises equal amounts of solder falls to the floor of the furnace, where it flows to
anhydrous soda ash and anhydrous borax forming a low corner and is collected. Some melters have
about 1-1/3% of the charge in melting 85-5-5-5 ingot used tunnel furnaces where the scrap is carried on
(Spendlove, 1961). After melting of the charge, the trays or racks through a heated tunnel by an endless
metal and dross are tapped off separately. A Kaldo conveyor. Some of the solder melts and falls from the
furnace can meet stringent environmental standards scrap while inside the furnace tunnel.
as it produces very low metal content, inert slags. The

45
CHAPTER 4: scrap, slags and oxide mill scale were placed in the B
list. The B list of materials is not covered by the Basel
Environmental Overview Convention as hazardous and, thus, not subject to
any export ban.

Annex VII defines the countries of the Convention that

Since the passage of the Clean Air Act of 1970, can trade in hazardous wastes (which include
numerous laws and regulations relating to improving valuable metal containing ashes, drosses and
human health and the environment have been residues, etc.) The criteria for defining countries in
promulgated by Congress and the federal and state Annex VII are of concern: the current impasse that
agencies that enforce them. This review is not meant restricts these countries to those predominantly from
to be a comprehensive review of all of them but, the northern industrialized hemisphere does not
rather, a sampling of some of the more significant reflect the sources for the hazardous wastes nor the
ones as to how they currently affect the way the necessity to treat these materials in countries other
secondary industry does business. than where they are generated (BIR Newsletter,
2002).
With a view to protect the environment by preventing
the production of waste and by organizing its disposal In 2001, the Basel Convention Conference of Parties
or recycling, administrations and legislators worldwide (COP5), a Protocol on Liability and Compensation,
have decided to take charge of all aspects of waste was adopted for damage resulting from transboundary
management — whether hazardous or not — movements of hazardous wastes and their disposal.
including the management of recyclable raw materials (www.basel.int/meetings/cop/cop5/docs/prot-e.pdf) A
that the industry recycles, processes and sells. declaration was also made reaffirming the Convention
Regulators tend not to distinguish between recyclable and supporting sustainable development. Areas
raw materials and waste and, in the process, create targeted for further study included waste minimization,
enormous obstacles for the entire reclamation and cleaner technologies, recovery and disposal of wastes
recycling industry. Metals should not be viewed as as well as waste prevention. The meeting for COP 6
wastes but rather as renewable resources that can be took place in Geneva in May 2002.
used again and again in new products, conserving
scarce resources, saving energy and preventing In the current decade (2000-2010), the Convention
pollution. Recycling should be given priority over plans on implementation and enforcement of treaty
disposal. The failure to look at the interplay of commitments. The other area of focus is the
markets, commodities and regulations before putting minimization of hazardous waste generation. A central
into effect new recycling regulations has ended up goal of the Basel Convention is Environmentally
being a very costly storage and disposal program. Sound Management (ESM). ESM addresses the issue
through an “integrated life-cycle approach.”
Transboundary movements of hazardous wastes can
take place only upon prior written notification to the
Basel Convention competent authorities of import and export. Shipments
made without such documents are illegal. Basel
One of the most contentious international agreements partnership initiatives include one on mobile phones
to surface has been the Basel Convention. In 1989, and another on personal computers. The purpose of
the Basel Convention on the Control of these initiatives is to advance management of
Transboundary Movements of Hazardous Wastes and obsolete materials and wastes globally.
Their Disposal came into force. Basel Convention is
under the United Nations Environment Program. It has OECD Rulings. On June 14, 2001, the Organization
since been ratified by more than 130 countries, for Economic Cooperation and Development (OECD)
including the United States, although the United adopted the final decision on the Control of
States has not passed legislation necessary to Transboundary Movements of Wastes Destined for
implement its participation in the Convention. The Recovery Operations. This decision streamlines the
U.S. Senate has not ratified the treaty, thus although OECD control system, is more economically efficient
the United States signed onto the Basel Treaty, the and environmentally safe, and enhances
U.S. is not a party to the treaty. harmonization with the Basel Convention. Three
OECD lists are replaced with two Annexes of the
In 1997, the Convention’s Technical Working Group Basel Convention, applying OECD green controls to
completed recommendations for assigning materials Annex IX wastes and OECD amber controls to Annex
to the “A list,” wastes characterized as hazardous, and VIII wastes. The OECD review mechanism is
the “B list,” wastes not inherently hazardous. Copper eliminated, while retaining the option of different
controls in exceptional cases. Examples of exceptions

46
for green and amber wastes, respectively, are: site, any person who at the time of disposal of
electronic scrap and drained motor vehicle wrecks; hazardous substances owned or operated the
and, flammable magnesium scrap and vanadium property, or any person who arranged for disposal or
residues. OECD membership is comprised of 30 transportation of hazardous substances at a property
countries including the EU and United States. The where a “release” has occurred. Section 107(b)
major points of “benefit” to the recycling industry provides three possible defenses to liability: an act of
include the following: (1) A new definition for a mixture God, an act of war, or action by a third party under
of wastes, specifying it as a waste that results from a certain circumstances.
mixing of two or more different wastes. A single
shipment consisting of two or more wastes, where To identify PRPs responsible for site contamination,
each waste is separated, is not a mixture of wastes. EPA reconstructs the history of operations that
(2) Green, as a control procedure, shall be applied to occurred at the site, by conducting an extensive
mixtures of green wastes for which no individual entry search through site, state agency and EPA files. Once
exists. On the other hand, where green waste is EPA has enough information to identify parties as
mixed with more than a minimal amount of amber potentially liable for contamination of a site, EPA
waste, or a mixture of amber wastes, it will be issues a general notice letter to each PRP, notifying
subjected to the amber control procedure. them of their potential liability.

The Superfund cleanup process starts with site

discovery by various parties including citizens, state
CERCLA Overview agencies and EPA regional offices. Once discovered,
the site is listed on the Comprehensive Environmental
The Comprehensive Environmental Response, Response, Compensation, and Liability Information
Compensation, and Liability Act (CERCLA), System (CERCLIS). This is EPA’s inventory of
commonly known as Superfund, was enacted by potential hazardous-substance release sites. EPA
Congress on December 11, 1980, and amended by evaluates these sites through the following steps:
the Superfund Amendments and Reauthorization Act
(SARA) on October 17, 1986. SARA provided the • Preliminary Assessment/Site Inspection
framework for the environmental taxes that establish (PA/SI) — site condition investigations
the Hazardous Substance Superfund and the Leaking
Underground Storage Tank Trust Fund. A trust fund of • Hazard Ranking System (HRS) Scoring —
$8.5 billion was authorized over 5 years. This law sites are screened to be placed on the NPL
created a tax on the chemical and petroleum
industries and provided broad federal authority to • Remedial Investigation/Feasibility Study
respond directly to releases, or threatened releases, (RI/FS) — the nature and extent of
of hazardous substances that may endanger public contamination is determined.
health or the environment.
• Record of Decision (ROD) — Cleanup
CERCLA establishes prohibitions and requirements alternatives are described for the NPL sites.
concerning closed and abandoned hazardous waste
sites, provides for liability of persons responsible for • Remedial Design/Remedial Action (RD/RA) —
releases of hazardous waste at these sites, and Plans are prepared and implemented for site
establishes a trust fund to provide for cleanup when remedy.
no responsible party can be identified. The law allows
for both short- and long-term response actions. Long- • Construction Completion — The completion is
term remedial actions permanently reduce the described.
dangers associated with releases of hazardous
substances. These actions can be conducted only at • Operation and Maintenance (O&M) —
sites listed on EPA’s National Priorities List (NPL). A Ensures that all actions are effective and
National Contingency Plan (NCP) provides guidelines operating properly.
and procedures for the release of hazardous
materials. • NPL Site Deletions — Removal of sites from
the NPL.
CERCLA, Section 107, designates those that can be
held liable for contamination and cleanup. When EPA A Superfund liability exemption for scrap recyclers
is investigating contamination at a site, any person was signed into law on November 29, 1999. Called
potentially covered by Section 107(a) can be the Superfund Recycling Equity Act of 1999, the
designated as a Potentially Responsible Party (PRP). exemption law applies to processors of scrap
PRPs include the current owner and operator of the materials, as well as to mills and other facilities that

47
are involved in reclaiming recycled materials. The Service has issued a health advisory that
EPA estimated the cost to remaining liable parties at recommends removing people from the site;
current Superfund sites would range between $156
million and $175 million. According to an ISRI list, 16 (2) EPA determines that the site poses a
Superfund sites would be affected by the new significant threat to public health; and,
legislation. Two of the sites are former brass
foundries, and another two are former scrap metal (3) EPA anticipates it will be more cost-effective to
reprocessing sites. use its remedial authority (available only at
NPL sites) than to use its emergency removal
Included in the 1999 Superfund liability amendment authority to respond to the site.
were scrap paper, plastic, glass, textiles, rubber,
metal, and spent lead-acid, nickel cadmium and other
batteries, as well as minor amounts of material
incident to, or adhering to, the scrap material as a Resource Conservation and Recovery Act
result of its normal use. Shipping containers with 30
liters to 3,000 liters capacity that had hazardous
(RCRA)
materials associated were not included.
RCRA was passed into law in 1976. The goals of the
law are to conserve energy and natural resources,
Transactions involving scrap metal must demonstrate
reduce the amount of waste generated and ensure
that the person making the transaction is in
that wastes are managed to protect human health and
compliance with all regulations or standards for
the environment. RCRA gives EPA power to make
storage, transport, management or other activities
and enforce regulations for managing many kinds of
associated with metal recycling and that the person
wastes. RCRA regulations apply to 3 kinds of waste
did not melt the scrap metal prior to the transaction.
management: municipal, solid waste landfills;
Melting, according to this definition, does not include
hazardous waste generators and transporters, and
sweating to thermally separate metals. Scrap metal is
treatment, storage and disposal facilities; and
defined as bits and pieces of metal parts or metal
underground tanks that store hazardous materials.
pieces held together with bolts or soldering.
Generally, sites that may be cleaned up under RCRA
Hazard Ranking System (HRS). First promulgated
or certain other laws will not be put on the NPL. By
July 16, 1982 (47 FR 51532), as Appendix A of the
“deferring” the cleanup authority to another program
NCP, it was revised December 14, 1990, in response
like RCRA prior to placement on the NPL, EPA can
to CERCLA Section 105(c). The HRS is the principal
reserve CERCLA response activity funding for sites
mechanism that EPA uses to place uncontrolled
that are not eligible to be addressed under other
waste sites on the NPL. It is a numerically based
federal authorities. If a site on the NPL falls under
screening system derived from the preliminary
RCRA authority, it usually will undergo RCRA
assessment and the site inspection. The sites with the
corrective action before Superfund remedial activity.
highest scores do not necessarily get the first
In some cases, the EPA may delete the site from the
attention. EPA relies on more detailed studies in the
NPL. For more information on the interface between
remedial investigation/feasibility study that typically
RCRA and CERCLA, see the September 24, 1996,
follows listing. Factors are grouped into three
EPA memorandum entitled Coordination between
categories: the likelihood that the site poses a
RCRA Corrective Action and Closure and CERCLA
hazardous substance release into the environment;
Site Activities.
the characteristics of the toxicity and waste quantity;
and the people or sensitive environments affected by
the release expected. Four pathways are scored:
ground water migration, surface water migration, soil
exposure (population affected), and air migration Toxicity Characteristic Leaching
(population and sensitive environments affected). The Procedure (TCLP)
site score can be high, even if only one pathway score
is high. Sites are placed on the NPL using the HRS. Section 1004 (5) of the RCRA defines hazardous
The second mechanism for placing sites on the NPL waste as solid waste that may “pose a substantial
allows states or territories to designate one top-priority present or potential threat to human health and the
site, regardless of score. A third mechanism allows environment when improperly treated, stored,
listing the site if it meets all three of the following transported or otherwise managed.” RCRA Section
requirements: 3001 charged EPA with the responsibility of defining
which specific solid wastes would be considered
(1) The Agency for Toxic Substances and Disease hazardous waste, either by identifying the
Registry (ATSDR) of the U.S. Public Health characteristics of the waste or listing particular

48
hazardous wastes. In response, the EPA identified 4 allows the use of two media. The medium used is
characteristics of hazardous waste: 1) toxicity, 2) determined by the solid waste alkalinity. The extract is
corrosivity, 3) reactivity, and 4) ignitability. The EPA analyzed for any of 39 listed toxic constituents. Details
also developed standardized procedures and criteria concerning TCLP procedures may be found in 40
for determining whether a waste exhibited any of CFR part 261, Appendix II, or in EPA’s publication
these characteristics. Testing procedures are detailed SW-846. The primary difference between EP and
in EPA’s report, Test Methods for Evaluating Solid TCLP is that TCLP covers a broader range of
Waste, SW-846 (1995). constituents and more accurately addresses the
leaching potential of wastes containing organic
The Extraction Procedure (EP) was the original test constituents.
developed by EPA to determine whether a waste
exhibits toxicity characteristics. A set of assumptions Two difficulties with the TCLP are: (1) it does not
was developed under a mismanagement scenario that account for the many parameters that affect leaching;
simulated a “plausible worst case” of and, (2) the TCLP has been applied in situations
mismanagement. Under this worst-case scenario, it where it is not appropriate. The latter is important
was assumed that hazardous wastes would be co- because a test designed to predict leaching in MSW
disposed with municipal solid waste (MSW) in a landfills may over or under predict leaching potential
landfill with actively decomposing material overlying in other scenarios. Ideally, testing procedures should
an aquifer. EPA felt this was justified given its bear a rational relationship to actual conditions under
mandate to protect human health and the which waste is managed and consider the many
environment. The toxicity of a waste was defined by parameters that affect the leaching behavior of
measuring the potential for toxic constituents present contaminants from the waste.
in the waste to leach out and contaminate
groundwater and surface water at levels of health or Suggested Improvements for the Toxic Characteristics
environmental concern. Specifically, the EP required Leaching Procedure (TCLP). In February 1999, the
analyzing a liquid waste or liquid waste extract to Science Advisory Board’s Environmental Engineering
determine whether it contained unacceptably high Committee (EEC) prepared a commentary to call
concentrations of any of 14 toxic constituents attention to the need for a review and improvement of
identified in the National Interim Drinking Water EPA’s current waste leachability testing procedure.
Standards (NIPDWS). To account for the likely dilution The Committee’s single most important
and attenuation of the toxic constituents that would recommendation is that EPA must improve leach test
occur as they traveled from the landfill to a drinking procedures, validate them in the field and then
water source, the EPA multiplied the NIPDWS by a implement them. They recognized that the TCLP
dilution and attenuation factor (DAF) of 100. The DAF might require the development of multiple leaching
of 100 was not derived from any model or empirical tests. The result may be a more flexible, case-specific,
data. It is an estimated factor. tiered testing scheme or a suite of related tests
incorporating the most important parameters affecting
In the 1984 Hazardous and Solid Waste Amendments leaching. Applying the improved procedures to the
(HSWA), Congress directed EPA to expand the worst-case scenario could ameliorate many problems
toxicity characteristic (TC) and reevaluate its use of associated with current procedures. Although the
the EP to determine the toxic characteristics of a Committee recognized that these modifications might
waste. In response, the EPA developed a new test in be cumbersome to implement, they felt this protocol
1986 — the Toxicity Characteristic Leaching might better predict leachability.
Procedure (TCLP). Two objectives were satisfied: (1)
a test to generate replicable results for organics, and The TCLP model assumes 5% industrial solid waste
(2) a test that could yield the same results for and 95% municipal solid waste in a sanitary landfill.
inorganics as the original EP test. The TLCP began The TCLP specifies a procedure for liquid wastes,
with the same assumptions that waste would be co- which are those with less than 0.5% dry solid material
disposed with actively decomposing municipal solid and for wastes greater than or equal to 0.5% dry solid
waste in a landfill. Thus, the test is designed to waste. Liquid waste is filtered through a fine glass
determine the mobility of toxic constituents in wastes fiber filter to form the TCLP extract, which is stored for
when exposed to organic acids. The adequacy of later analysis. The solid phase may then undergo size
DAFs of 100 was confirmed for all of the listed toxic reduction. The EP required particle size reduction
constituents. through a 9.5-mm sieve. This requirement is retained
by the TCLP. In the TCLP, the waste must be ground
After particle size reduction, a liquid extract is or milled until it passes a 9.5-mm sieve. Two
obtained by exposing the waste to a leaching medium extraction fluids are used: One is a pH 2.9 acetic acid
(also called extraction fluid). In contrast to the EP, solution for moderately to highly alkaline wastes and
which specified only one leaching medium, the TCLP the other is a pH 4.9 acetate buffer solution that is

49
used for all other wastes. Although defined as a test of Leachability Phenomena: Reduction in particle size
toxicity characteristics of contaminants in a waste, affects testing of volatile compounds. The EPA
TCLP has found a variety of other applications. For concluded that the advantages of particle size
example, TCLP has been used in administrative reduction outweighed the potential problems.
delisting procedures as an end point test for clean-up However, the ECC recommends that EPA reconsider
standards and as a source term for risk the issues of volatile loss and/or increases in
assessments/site closure modeling. constituent solubility.

Kinetics: The TCLP is based on an arbitrarily chosen Aging: At present, wastes are tested at the time of
extraction time of 18 hours. Timing of the leaching generation. A lapse of considerable time between
process is difficult. Some solid matrices display a long generation and dumping may allow chemical or
period of slow release that may be more relevant to physical transformations to take place.
the protection of health and the environment than the
early, fast release. For some constituents, the TCLP Volatile Losses: Volatile losses may occur during the
may not measure this slow release. leaching procedure and analysis. When addressing
volatile compounds, the most important pathway for
Liquid/Solid Ratio: The TCLP uses a 20:1 liquid-to- release to the environment may not be leachability. In
solid ratio, chosen for analytical and administrative these cases, the mass release of volatiles should be
procedural purposes. Liquid-to-solid ratios can vary considered.
depending upon field conditions. Degree of saturation,
weather, climate and infiltration rates as well as Interaction with other wastes: The TCLP assumes
hydrological impacts of engineered systems can result municipal solid waste leachate governs leachate
in substantial deviations in this ratio. chemistry and rate of release. In the presence of co-
solvents, solubility of the organic phase, rather than
pH: The TCLP assumes that, in the MSW landfill the aqueous phase, may control the leachate
scenario, the disposal venue (not the waste) governs concentration. Surfactants may also mobilize
the leaching fluid chemistry. The two current TCLP hydrophobic contaminants.
leaching fluids cannot account for the diversity of
wastes and waste management conditions. Many Field Validation of the Tests: The 1991 EEC
contaminants do not leach from waste matrices. commentary, “Leachability Phenomena,” suggested
Higher pH values than that assumed cause the higher that field tests were needed to validate the tests
than predicted concentrations of regulated metals that before broad application. The TCLP was not intended
form oxoanions (e.g. Sb, As, Mo, Se and V) in the to be representative of insitu field conditions, but
MSW leachate. Similarly, aggressive simulated MSW rather of a generic MSW landfill worst-case scenario.
leachate (TCLP fluids) may significantly over predict There should be a means for reconciling any leach
the availability and mobility of contaminants in natural test results with expected or observed field leachate
settings. concentrations. A model should be developed.

Colloid Formation: Colloids may be formed during the Multiple Extraction Procedure (MEP). The MEP is
end-over-end agitation required in the TCLP testing. designed to simulate the leaching that a waste will
The aggressive agitation can dislodge or otherwise undergo from repetitive precipitation of acid rain on a
create colloidal particles, which may pass through the landfill to reveal the highest concentration of each
filtering process and subsequently be analyzed as constituent that is likely to leach. This test is currently
part of the extract. An over prediction of the aqueous used in EPA’s delisting program and has been
phase as a constituent may result from hydrophobic designated method 1320 in the SW-846 manual. The
organics and metals that preferentially bind to these MEP is intended to simulate 1,000 years of freeze-
colloidal particles. and-thaw cycles and prolonged exposure to a
leaching medium. Reportedly, one advantage of the
Particle Size Reduction: TCLP particle size reduction MEP over the TCLP is that the MEP gradually
requirements may not represent field conditions. removes excess alkalinity in the waste. Thus, the
Monolithic wastes have a lower leaching potential leaching behavior of metal contaminants can be
caused by physical stabilization and the resulting evaluated as a function of decreasing pH, which
increase in length of diffusion pathway from waste into increases the solubility of most metals.
the leachate. Additionally, some processes also
provide for chemical stabilization by binding heavy
metals in insoluble hydroxide and other complexes.
Reductions caused from solidification/stabilization of
monolithic wastes are ignored.

50
Hazardous Wastes chemicals released to the environment by
manufacturers or businesses in the United States.
Under 40 CFR Chapter 1 (7-1-98 edition) solid wastes The inventory is updated yearly and provides a means
that are subject to regulation as hazardous wastes are for interested persons to access information on toxic
identified under parts 261 through 265, 268, and parts chemicals being released, stored or transferred to
270, 272 and 124. Subpart A of the Chapter defines their communities. This data has been made available
the terms solid waste and hazardous waste. It also under the Emergency Planning and Community Right-
identifies those wastes that are subject to regulation to-Know Act (EPRA) of 1986. Under the Act,
under parts 262 through 266, 268, and 270 and manufacturers and businesses are required to report
establishes special management requirements for locations and quantities of toxic chemicals if the
hazardous waste produced by conditionally exempt facility produces substantial amounts (more than
small-quantity generators and hazardous waste that is 25,000 pounds). This reporting became more
recycled. Subpart B sets forth the criteria used by comprehensive following the Pollution Prevention Act
EPA to identify characteristics of hazardous waste (PPA) of 1990. The strategy focuses less on tracking
and to list particular hazardous wastes. Subpart C and managing the waste and more on avoiding them.
identifies characteristics of hazardous wastes. Facilities are now required to indicate amounts of
Subpart D lists particular hazardous wastes. chemicals that are recycled, used for energy recovery,
and treated on site. Source reduction activities are
In February 1999, EPA proposed a rule to promote also noted. TRI is available on the Internet
metal recovery from the hazardous waste water (www.epa.gov/tri) and in various types of publications.
treatment sludge (F006, as regulated under RCRA). It In addition, the Agency for Toxic Substances and
was proposed to encourage the legitimate recovery of Disease Registry (ATSDR) maintains the Hazardous
metals from F006 waste that would otherwise be land- Substance Release/Health Effects Database
disposed. The F006 wastes generated from (HAZDAT). Chemicals on the Toxic Release Inventory
electroplating processes in the metal finishing industry include antimony, arsenic, barium, beryllium,
generally contain recoverable amounts of metals. cadmium, chromium, cobalt, copper, lead,
Although some of this sludge is recycled for metals manganese, mercury, nickel, selenium, silver, thallium
recovery, a large percentage (according to EPA) is and zinc compounds, in addition to a long list of
land-disposed. By minimizing the economic barriers to organic chemicals, acids and gases.
recycling of F006 waste through metals recovery, EPA
feels this route will be more commonly sought. EPA The National Risk Management Research Laboratory
proposed to allow generators of F006 waste up to 270 has developed and is continuing to expand a
days to accumulate the waste on site without requiring database on the effectiveness of proven treatment
a hazardous permit, provided certain safeguard technologies in the removal/destruction of chemicals
conditions are met. Currently, only 90 days are in water, wastewater, soil, debris, sludge and
allowed. The EPA feels that the increased time will sediment. This database gives performance data on
allow larger shipments of F006 waste to be shipped, numerous technologies and is called the Treatability
reduce transportation costs and provide additional Database (TDB). TDB is available from NRMRL in
incentive to recover metals rather than dumping the Cincinnati, Ohio.
material. According to some industry sources,
however, this rule falls short of providing the
necessary incentive required for increased recovery of Lead in the Workplace Directives (OSHA)
metals from F006 sludges. Because these materials
are classified as hazardous wastes, they are subject The Occupational Office of Safety and Health
to all the shipping, handling and licensing Administration (OHSA) promulgates workplace and
requirements of hazardous materials. EPA has safety rules for U.S. industries. On November 14,
allowed a variance to at least one company in 1978, OSHA defined the lead standard (29 CFR
Phoenix, Ariz., in an effort to promote recycling and to 1910.1025) (43FR 52952). This standard required that
recognize that when used for metal recovery, these employers achieve a lead exposure limit (PEL) of 50
materials are analogous to virgin raw materials used µg/m3 based on an 8-hour time-weighted average
by primary smelters. (TWA)(29CFR 1910.1025(c)). Both industry and labor
challenged the standard. The court found that OSHA
had failed to establish feasibility of meeting the PEL
Toxic Release Inventory (TRI) System for 38 of the industries covered and remanded OSHA
and Other Databases to reconsider the ruling.

The Toxic Release Inventory (TRI) system is a In December 1981, OSHA published its new findings
database of more than 300 designated toxic for all but nine of the industries. The nine industries
included brass and bronze ingot

51
manufacturing/production, collection and processing and baghouse maintenance operations. Therefore,
of scrap, nonferrous foundries and secondary copper OSHA assumed the burden for proving economic
smelting. In March 1987, the court asked OSHA to feasibility in any enforcement proceeding under
reconsider the application of the ruling for these paragraph (e) (1) of the Lead Standard concerning
remaining nine industries. On July 11, 1989, OSHA these operations. OSHA is allowing employers 6
filed with the court additional reasons that compliance years from the date the court lifts the stay to comply.
with the PEL solely by means of engineering and work Follow-up instructions listing the new compliance date
practice controls was feasible for eight of the will be issued at that time.
remaining nine industries. OSHA felt that the ninth
industry, nonferrous foundries, could comply with the On February 27, 1997, the Directorate of Compliance
PEL by means of engineering and work practice Programs published directive number CPL 2-2.67 to
controls, but it was not economically feasible for small change compliance requirements and compliance
nonferrous foundries to comply with paragraph (e) (1) dates for enforcement of the engineering and work
of the ruling (54 FR 29142). Later, OSHA published practice controls provisions of the Lead Standard (29
on January 30, 1990, a determination that the small CFR 1910.1025 (e) (1). The stay on enforcement of
nonferrous foundries could comply and achieve an 8- paragraph (e) (1) of the Lead Standard as it applies to
hour TWA airborne concentration of lead of 75 µg/m3 the brass and bronze ingot manufacturing industry
(55 FR 3146). Six of the nine industries challenged has not yet been lifted by the court. Until the stay is
OSHA’s findings including brass and bronze ingot lifted, employers in this industry must continue to
manufacturing, collecting and processing scrap, the control lead exposures to 200 µg/m3 solely by
nonferrous foundries and copper smelting. engineering and work practice controls, and to 50
µg/m3 by some combination of engineering and work
On March 8, 1990, the court lifted the stay on practice controls and respiratory protection. Six years
paragraph (e) (1) for all remanded industries (39 after the judicial stay of the Lead Standard is lifted by
industries), except the six that challenged the the court, the Compliance and Safety and Health
feasibility findings. The 39 industries were given two Officer (CSHO) shall determine whether the employer
and one-half years to comply with the PEL. in the brass and bronze ingot manufacturing industry
Eventually, on July 19, 1991, the court reaffirmed is in compliance with all provisions of the Lead
OSHA’s feasibility findings for five of the six contested Standard.
industries, and lifted the stay. These industries
included the nonferrous foundries (large and small),
secondary copper smelting, and collection and
processing of scrap. Employers in these three Clean Air Act Ruling.
industries were given until July 16, 1996, to comply.
The Clean Air Act is the comprehensive federal law
With regard to the brass and bronze ingot that regulates air emissions from area, stationary and
manufacturing, however, the court concluded that, mobile sources. This law authorizes the U.S. EPA to
while OSHA had shown it was technologically feasible establish national Ambient Air Quality Standards
to comply, it had not shown it was economically (NAAQS) to protect public health and the
feasible to do so. The court remanded that portion of environment. The Act was amended in 1977 to set
the record to OSHA for additional consideration and new goals and dates for achieving NAAQS deadlines.
continued the stay of paragraph (e) (1) for the brass The 1990 amendments were intended to meet
and bronze ingot industry. insufficiently addressed problems such as acid rain,
ground-level ozone, stratospheric ozone depletion and
OSHA concluded that an 8-hour TWA airborne lead air toxics. On February 28, 2001, the U.S. Supreme
concentration of 75 µg/m3 was the lowest Court ruled unanimously that federal law doesn’t allow
economically feasible level that could be achieved by the EPA to consider expense to industry when it sets
means of engineering and work practice controls in clean-air standards and permissible pollution levels.
the brass and bronze ingot industry as a whole (60 FR The Court agreed with the fundamental principle that
52856). Then on June 27, 1995, the Brass and the Clean Air Act was designed to protect people’s
Bronze Ingot Manufacturing association and the health without regard to cost. However, the ozone
Institute of Scrap Recycling Industries entered into an standards can’t be implemented until the case goes
agreement with OSHA acknowledging that this level back to the U.S. Court of Appeals for the D.C. Circuit
was economically feasible for the industry as a whole. to assure that EPA reaches a lawful and reasonable
Based on the record, OSHA also recognized that most interpretation of ozone standards and enforcement
employers could not achieve the 50 µg/m3 PEL policies. Beyond the cost factor, the Court ruled that
without supplemental use of respiratory protection, Congress did not unconstitutionally delegate its power
and that it was not economically feasible to achieve to EPA. The rules affect airborne soot and smoke
even an 8-hour TWA of 75 µg/m3 in the briquetting from trucks and power plants, as well as smog or

52
ground-level ozone from chemical plants and other new facility be constructed, brief recommendations
sources. The 1997 standards limit ozone to 0.08 parts were proposed in both reports to ensure that any
per million, instead of 0.12 parts per million under the potential emissions will be appropriately controlled.
old requirement. Baghouses were identified as the most effective
particulate matter (PM) control devices to be used on
For current rules and regulations for clean air act cupolas and other furnaces. Iron and steel scrap with
ruling, seek www.epa.gov on the internet and select baghouse control are subject to a PM limit of 0.002
Clean Air Act. Information may also be found for the gr/dscf, or less. EPA chose to apply a PM limit of
Clean Water Act on this site. 0.002 gr/dscf as GACT to all melting furnaces and
other furnaces that process molten metal at a new
The U.S. EPA published new rules in the Federal secondary copper smelter. This is consistent with the
Register for National Emission Standards for UN Environment Programme’s guidelines on
Hazardous Air Pollutants (NESHAP) on January 23, performance standards for new secondary copper
2007 (Vol. 72, No. 14). smelters (available at http://www.pops.int/documents).
These guidelines recommend PM removal systems
This followed the proposed rules published on such as fabric filters or baghouses and state that
October 6, 2006 in the Federal Register. With regard these systems should achieve a PM level of 5
to rules applying to the secondary copper smelter milligrams per cubic meter (.002gr/dscf) for new
industry, both reports are worth reading. The principal secondary copper smelters. The final rule (Jan 23,
observations called attention to the fact that there are 2007) applies only to secondary copper smelters and
currently no secondary copper smelting facilities does not apply to copper, brass, and bronze ingot
operating in the United States that qualified for makers or remelters that may also be included under
specific air quality applications. However, should any this NAICS code.

53
CHAPTER 5: • Loss of production lines and management
Problems and Solutions positions associated with plant closings

• Diminishing approved landfill space

accompanied by increased tipping fees

The Problems • Continuing pressure from state regulatory

officials to comply with more strict
The responsibilities placed on the secondary copper environmental and labor regulations, and
and copper alloy industry by the steadily increasing
application of environmental laws have been • Lack of capital at small-scale operations for
enormous, ranging from increased paperwork and retrofitting and/or modifying basic pollution
reporting requirements to the need for installing control processes.
expensive equipment. The paperwork, reporting
requirements and mandatory cleanup procedures, Problems for most of the secondary industry also
which the federal agencies use to control the way the emanate from the potential responsible party (PRP)
industry does business, are not only expensive, but aspects of the Superfund law. The potential here is to
also counter productive. The result, in many cases, be named liable for expensive cleanup solely because
has been the shut down of useful, necessary you may have sold raw material to a firm that is
businesses. One has to look only at the demise of the currently on the CERCLIS and listed on the NPL. This
secondary smelter industry in the United States to see has happened to a number of firms that did business
what has happened and what will continue to happen. with the Jacks Creek/Sitkin Smelter and Refinery, for
example. This kind of approach to solving Superfund
The last operating secondary smelter was under suit finances is sure to have far-reaching repercussions in
for allegedly dumping undesired water and closed in the metal processing industry as scrap dealers think
2001. This kind of threat and action has become a twice about shipping materials to certain firms.
way of life for this segment of the metals industry. The
expense of extensive litigation, permitting procedures Liability concerns have been enormous barriers to
and requirements for new equipment has resulted in development, redevelopment and cleanup
the eventual shut down of most of these plants and technologies. Because financial institutions can be
their removal from a very important role in the U.S. liable for cleanup costs when they acquire the
recycling industry. Even so, some other parts of the properties through default, they are unwilling to
secondary industry, with more firm financial backing, provide loans for development.
are attempting to meet similar problems head on and
have enthusiastically embraced new technology and A whole set of new problems will arise should the by-
improved techniques as a better way of doing products of metal processing become controlled
business. substances under RCRA. Shipment of these materials
to others would become an expensive proposition. In
The shutdown of secondary smelter and refinery short, the markets for these materials would change
capacity has presented the remainder of the industry drastically. Most producers would have to pay for their
with several problems. Aside from the problem of disposal, rather than receive money for their valuable
finding new markets for the sale of lower grades of metal content. Processing facilities also would be
scrap and copper processing by-products, which were reluctant to take these materials, owing to their new
previously processed by these companies, there is a hazardous classification.
growing problem for others in securing the relatively
inexpensive raw material that these businesses could Electronics recycling has become a significant
provide in return. The recent economic uncertainty of concern in recent years. Computers, in particular, are
the international copper market, with its continuing becoming obsolete more quickly than ever (the typical
over capacity and lower prices, has added extra computer now has a life span of 2–3 years, down from
penalties to the secondary market. Collection and use 5 years in 1997 (Recycling Today, Feb. 2002). In the
of old scrap, in particular, suffered in recent years; the United States, between 14 and 20 million computers
supply was not as available as it might have been become obsolete every year. According to a recent
under better circumstances. USGS study (July 2001), obsolete computers contain
significant amounts of recoverable materials, including
Problems confronting the foundry industry include metals. Although some of the metals are listed as
(Regan and Contos, 1990): hazardous by the RCRA, most are recoverable and
sought after, such as copper and the precious metals.
• Market pressure from foreign competitors, One metric ton of circuit boards can contain between
limiting selling price of domestic products 80 and 1,500 grams of gold and between 160 and 210

54
kilograms of copper. About 4.3 and 4.6 thousand brass are used to construct a typical light water
metric tons of copper were recovered in the United reactor facility. Copper is used in turbine generators,
States by recyclers in 1997 and 1998, respectively. In reactor equipment, heat transfer systems and
1998, about 2.6 million personal computers were miscellaneous instrumentation and control systems.
recycled in the United States. Much of the metal at DOE facilities and NRC licensed
sites is not contaminated, and can be released without
Some recyclers have been shipping components a problem. It is estimated that copper associated with
overseas for dismantling by hand. Because labor is electrical plant equipment amounts to about 557 tons
less expensive in China and Taiwan, and hand and that the total mass of uncontaminated (clean)
dismantling results in less waste than shredding, copper is about 580.3 tons. The remainder, only about
much of this material had been headed there. This 62 tons, is slightly contaminated. At the end of 1999,
traffic may not continue at the same pace in the there were 104 operating nuclear power reactors and
future, owing to a new environmental awareness in 37 operating nonpower reactors in the United States.
China and new tariffs against the import of scrapped The normal duration of a nuclear power reactor
electronic parts. China threatened to crack down on license is 40 years, some with 20 year extensions.
illegal imports of junked computers and other Shutdown dates range from 2006 to 2030, among the
electronic scrap. In Guiyu, China, stacks of broken facilities currently licensed to operate. The total
computers and electronic parts filled unused rice amount of potentially contaminated recyclable metal is
paddies, and circuit boards were being melted over not much compared with the millions of tons of refined
open fires. A substantial tariff was levied in May 2002 copper consumed by the U.S. industry each year.
on what China called “Class 7” copper scrap and However, this small amount of contaminated metal is
blocked containers of copper scrap from entering the of great concern to the processing industry. According
country. Some U.S. brokers considered the measure to some sources (www.sierraclub.org) more than 1.6
severe and likely to affect U.S. copper exports to million tons of iron, steel, aluminum and copper metal
China. This did not have an immediate effect, since were in storage by 1997 waiting for the EPA green
U.S. scrap exports to China continue unabated light.
through 2007. China’s scrap imports in 2006 and 2007
were at record levels (Table 4). In the meantime, with Increasingly, EPA has received complaints from scrap
commodity prices at record highs and innovative dealers and refiners that in receiving hot scrap, they
electronics recycling methods becoming increasingly are having to pay for cleanup when their scrap yards
cost effective, new value is being found in all post- and plants become contaminated. As a general rule,
industrial and post-consumer scrap. copper refining facilities will not accept material that is
radioactive. Those that have unwittingly done so by
In 1984, Noranda in Canada began processing small mistake have paid millions of dollars to undo the
amounts of electronic scrap and, by 1999, was the damage. One company in the early 1990s
largest electronics recycling plant in North America unknowingly shipped some radioactive slag, which
(USGS, 2001). There is value contained in the resulted from fire-refining a contaminated bus bar, to a
monitors and CRT’s, but Noranda must charge a fee company in Canada for further processing. The
for cover the handling costs. The fee is normally Canadian company did an analysis and refused the
several hundred dollars per metric ton. shipment, resulting in costly storage, permitting,
shipment and hazardous dump fees for the victimized
Radioactive metals. As nuclear plants are U.S. company.
decommissioned, storage and disposal of the slightly
radioactive scrap metals derived from them become
more of a problem. The Environmental Protection
Agency (EPA) and Nuclear Regulatory Commission Industry Solutions
(NRC) have been concerned about risk imposed on
the public from the recycling of radioactive In talking to industry representatives, one finds
contaminated metals. Since the mid-1990s, EPA has enthusiasm for the various methods and equipment
been studying the risk involved with recycling of they have developed for coping with heightened
slightly radioactive metals from NRC licensees. More environmental awareness. Most of the surviving
recently, the NRC has been looking into the feasibility industry has managed to solve many of the pollution
of recycling dismantled nuclear plant metal through problems in their particular part of the industry and are
commercial metal processors. Unfortunately, there are proud to be a part of the solution. In addition to solving
very few qualified secondary copper refiners the environmental and labor health problems posed
remaining in the United States. by EPA and OSHA, many in the industry also are
striving to achieve ISO 9000 and ISO 14000 quality
According to Bryan and Dudley (1974), approximately standards to maintain high-quality goals in their
694 tons of copper, 250 tons of bronze and 10 tons of production processes.

55
Some companies have made strategic investments in strategies for maximizing the use and disposal of
their businesses during the slower economic times of foundry industrial by-products prompted a group of
the past several years. Melting and fabricating foundries in Pennsylvania to establish the Process
processes have been rethought and retooled to run Recovery Corporation, Inc. (PRC). The PRC is
with fewer people. Many of these new fabricating headquartered in Reading, Penn., and represents
methods and machines have been in-house about 33 foundries in that area. The general goal of
inventions and are unique to the user plant. Simple the PRC is to establish a centralized facility for the
measures such as using a different melting additive collective management of residual (non-hazardous)
have cut down copper loss in skimmings and drosses. solid wastes (RSW) from its members. The PRC
A new baler installed saves about $50,000 per year in provides options for reclamation of foundry sand for
electrical costs. The current market downturn has reuse, finding alternative uses for other foundry
provided an opportunity for some firms to reevaluate wastes and, lastly, managing ultimate residuals by
current operations to ensure maximum efficiency and landfilling. Researchers from Pennsylvania State
recovery rates. University have assisted the PRC in several aspects
of the project dealing with engineering and the
Some secondary metal processors have instituted environment. The individual foundry members
their own slag and residue cleanup and recovery contributed technical and operating data to the PRC,
systems, preferring to retain all benefits to their own as well as funding for its efforts. (Regan and Contos,
company. For some, this has been a rewarding effort, 1990).
but this is not possible at all sites. In addition to the
significant financing and risk required, there are Management Systems and ISO Standards.
problems of adequate space and permits. Although Management systems differ from the traditional kinds
exports to other nearby countries, such as Canada of functional standards enforced by OSHA and EPA.
and Mexico, are alternatives, this has not been Management systems standards define the processes
pursued as broadly as one might have expected. and documentation that an organization or company
Exports of lower-graded (and less valuable) scrap should implement, rather than defining the limits or
have been lower than expected, owing to the low price quantitative objectives of performance. Two
of copper and the strong dollar over the past several international management systems currently exist: the
years. Of course, the high-grade slags (up to 65% ISO 9000 quality management system standards and
copper) generated from fire refining have found, and the ISO 14000 environmental management systems
will continue to find, ready export markets. standards.

Unfortunately, one industry solution to the weakening The ISO 9000 series is published internationally under
availability of old copper-base scrap has been to put the auspices of the 90-country membership of the ISO
up for sale or shut down operating smelters and (International Organization for Standardization).
associated refineries. This could spell trouble for the According to ISO procedures, all ISO standards must
recycling industry, since the recourse of last resort be reviewed and revised or reaffirmed at least every 5
may be dumping in landfills those materials that years. These standards were derived from the 1987
previously had been usable and valuable residues. British Standards Institute after they were revised to
This is also potential trouble from a national security include service providers as well as manufacturing
point of view. Secondary smelters are essential during companies. In 1994, ISO 9000 was again revised and
wartime buildup and scarcity of primary raw materials. published internationally. In particular, the sections
covering Process Control, Corrective Actions and
In 1999, the National Electrical Manufacturers Servicing were strengthened and clarified. Today, the
Association (NEMA) petitioned the EPA to delist ISO 9000 Standards Series has all but replaced other,
copper from its Toxic Release Inventory (TRI) more parochial standards for doing business and
because it felt that recycling prevents most copper guaranteeing quality. In only a few short years, the
from entering the environment. There also was term ISO 9000 has become synonymous with quality
growing evidence that copper was not detrimental to in almost every language used to conduct trade and
the environment as previously theorized. Public commerce. These standards require strict methods of
access to information on the TRI list could cause procedure and labor training. The results have been
undue public concern and stigmatize some of its better, more streamlined operations and improved
members. In 1997, the TRI report indicated that markets for their products.
34,500 tons of copper had been released to the
environment. A similar petition to delist copper in 1996 The American National Standards Institute (ANSI) and
was rejected (American Metal Market, 1999). the Registrar Accreditation Board (RAB) established
an accreditation system in response to the need to
Process Recovery Corp. The need for improved, accredit registration bodies as required by ISO 14001,
cost-effective technologies and management 14010 and 14011. The ANSI-RAB National

56
Accreditation Program Criteria (NAP), published Education Initiative to inform consumers about
September 13, 1996, specifies requirements for a recycling and reuses of used electronics, including
registration body. Audit teams from the registration computers.
body go out to organizations seeking registration and
compliance with ISO 14001 standards. ISO 14001 Some U.S. and Canada scrap handlers use shredders
requires an organization to have an environmental on electronic scrap, but some also hand dismantle
policy statement that includes: a commitment to these materials, charging a fee to make the process
prevention of pollution, a commitment to continual economically viable. When considering electronics,
improvement, and a commitment to compliance with there are environmental concerns with the disposal of
relevant legislation and regulations. Top management these items, as they contain potential hazards. Some
is to define the organization’s environmental policy organizations take older computers and parts for
and ensure that it includes a commitment to comply reconstruction, redistribution and resale. Some parts
with relevant environmental legislation and of Europe and Mexico, reportedly, have found use for
regulations. computers that might be considered outdated by U.S.
standards. However, reuse is not possible for all of the
In September 1996, ISO determined that there was discarded electronics. Most recyclers test for reusable
insufficient support to proceed in developing components before completely dismantling the items.
international voluntary consensus standards on What cannot be reused can be processed, usually by
occupational health and safety management systems hand dismantling, or by shredding, to retrieve metals
(OHSMS). One of the reasons stated was that such as copper, steel, aluminum and the precious
national or regional standards are different, owing to metals.
different socioeconomic conditions and cultural
differences. There is little to harmonize, and, A handful of states are mandating “take-back”
therefore, an ISO OHSMS standard would not programs and industry has begun to respond. Sony
facilitate international trade. In addition, companies Corp announced in August 2007 a recycling scheme
have not had sufficient experience in evaluating the to process Sony-brand electronics castoffs. Waste
benefits and effectiveness of ISO 9000 quality Management Inc., Sony’s partner in this venture
management systems and ISO 14000 environmental already sells materials such as copper retrieved from
management systems standards. The costs e-waste. Sony will try to raise awareness and make
associated with implementing an OHSMS standard recycling a lot more convenient than it is today.
would outweigh the potential benefits. Treating recycling as a business, not a money pit,
marks a turning point for the industry.
Electronic Scrap. Although handling electronic scrap
has been a growing problem in the United States, new Lead in Potable Water. On September 20, 2007, the
companies are being formed and improved methods American Foundrymen’s Society (AFS) held a
are being adapted to address the problem. The meeting to discuss the implications of the recent
International Association of Electronics Recyclers potential California legislation (AB1953) that will
estimates that there are about 400 electronics further restrict the acceptable level of lead in potable
recycling companies in the United States, and that the water applications. The Copper Development
electronics recycling process yielded about 410,000 Association and the industry have been working on
tons of recyclable materials in 2001 lead substitution in several copper alloys for some
(http://www.iaer.org). The IAER estimates that 3 billion time. Although bismuth (SeBiloy and other
consumer electronic units will be scrapped during the alloys)alloys have been consistently suggested as
rest of this decade, or an average of 400 million units leading candidates, the limited source of the metal
per year. The electronics recycling industry is has been a principal worry. There are several of these
expected to increase capacity by a 4 or 5 times factor alloys now available on the market. The alloys known
by the end of this decade. as SeBiloys use a combination of bismuth and
selenium to replace lead. These alloys were
The U.S. EPA provides information on how and where developed by a broad-based consortium led by the
to donate, or to safely recycle old electronics – namely American Foundryman’s Society with funding and
TVs, computers and cell phones—with links to vendor technical input from the CDA and the Brass and
and retailer recycling program information. Bronze Ingot Manufacturers, and including several
(www.epa.gov) Another site, E-cycling Central foundries and plumbing products producers. While the
(www.eiae.org) from the Electronic Industries Alliance, basic properties tend to be comparable to their leaded
offers a state-by-state recycling directory and counterparts, they are more expensive. It is not known
information about national programs. The how widely these alloys can be practically applied.
Environmental Issues Council of the Electronic
Industries Alliance has organized the Consumer

57
Government Solutions are currently stalled, while debate over retroactive
liability continues. To date, 36 states reportedly have
Because liability concerns have been a problem, implemented, or are in the process of implementing,
interest in brownfield redevelopment has surged over voluntary cleanup programs. A state’s brownfield
the past decade, owing to a combination of federal, cleanup program can provide relief only from action
state and local programs aimed at reducing regulatory under state law, and the possibility of federal action
burdens and mitigating liability. Congress also has cannot be eliminated. In 1996, EPA had signed State
recently been taking an interest. A brownfield is a site, Memoranda of Agreements (SMOAs) with 11 states to
or portion thereof, that has actual or perceived help them develop cleanup programs, giving the
contamination and an active potential for states a lead role in addressing sites not on the
redevelopment or reuse. CERCLA establishes the Superfund National Priority List, and delineating
liability regime that affects brownfield sites as well as clearly the roles of states and the EPA.
Superfund sites. While brownfield cleanups typically
cost much less, the contamination extent is usually In November 1999, Congress passed the Superfund
unknown. Several state environmental agencies, the Recycling Equity Act of 1999, which exempted a
USEPA and other governmental agencies have been broad scope of scrapped material from liability to
working to develop procedures to ameliorate and “promote the reuse and recycling of scrap material in
develop brownfield sites. The USEPA’s Brownfields furtherance of the goals of waste minimization and
Initiative strategies include funding pilot programs and natural resource conservation, while protecting human
other research efforts, clarifying liability issues, health and the environment” (S.1528). While including
entering into partnerships, conducting outreach a wide variety of scrapped, economically viable
activities, developing job training programs, and materials, this bill fell short of also including those
addressing environmental justice concerns. The valuable recyclable secondary by-products of copper
USEPA has been working with states and and copper alloy scrap processing that also have
municipalities to develop guidance that will provide markets.
some assurance that, under specified circumstances,
prospective purchasers, lenders and property owners A new EPA rule, intended to clarify RCRA, was
do not need to be concerned with Superfund liability. proposed in June 2002. The new rule was expected to
ease restrictions that have caused many cities and
In 1977, Congress enacted the Community recyclers to shy away from recycling cathode ray
Reinvestment Act (CRA) to require banks, thrifts and tubes (CRTs), which is one of the largest sources of
other lenders to make capital available in low- and lead in solid waste dumps, and cabling and older
moderate-income urban neighborhoods. casings, which contain polyvinyl chloride (PVC). Other
Environmental concern and financial liability for nations are taking a look at how to handle electronics
cleaning up these sites has made potential investors in their recycling and waste streams, and
reluctant to undertake this development. Rather than manufacturers are also involved.
reuse former urban industrial sites, businesses have
instead moved to suburban or rural Greenfield areas, The Organization for Economic Cooperation and
which carry fewer risks to development. Development (OECD) began examining the
electronics waste issue in October 2001. The OECD
On September 30, 1996, as part of the Omnibus Working Group on Waste Prevention and Recycling is
Appropriations Bill, the Asset Conservation, Lender developing a program to give greater assurance of
Liability, and Deposit Insurance Protection Act of 1996 proper management of recyclables being exported
was passed. The Act includes lender and fiduciary and to take a close look at management of electronics
liability amendments to CERCLA, amendments to the recycling. Guidelines are expected for members who
secured creditor exemption set forth in Subtitle I to rely on third party auditing to ensure that hazardous
RCRA, and validation of the portion of the CERCLA materials are handled in a safe manner. The Basel
Lender Liability rules. In addition to specific guidance, Action Network is also working toward developing
the EPA is exploring other ways to address the fear guidelines to stop the export of hazardous wastes.
that affected parties may have concerning Superfund The European Union has proposed a Waste Electrical
liability at previously used properties. and Electronic Equipment (WEEE) Directive that will
give manufacturers responsibility for recycling their
On August 5, 1997, the Taxpayer Relief Act was products when they are discarded. In the United
passed and included a new tax incentive to spur the States, some manufacturers and retailers have helped
cleanup and redevelopment of brownfields in states and municipalities sponsor electronics recycling
distressed urban and rural areas. In 1997, several bills programs. Some states have also enacted legislation
also were introduced in Congress to establish a to place restrictions on the disposal of products
process and funding for states to work with the EPA containing hazardous material to encourage
and industry in voluntary cleanup programs. The bills

58
manufacturers to reduce the use of certain materials Radioactive Metals. In July 1997, S. Cohen and
(Recycling Today, Feb. 2002). Associates, under contract to EPA, produced a report
on recycling of scrap metals from nuclear facilities
In September 2003, California passed the Electronic (Evaluation of the Potential for Recycling of Scrap
Waste Recycling Act, the first law of its kind in the Metals from Nuclear Facilities, July 15, 1997). A
United States. It bans the export of e-waste to foreign further analysis containing revised impacts on the free
countries that don’t meet environmental standards. release of scrap metal from nuclear facilities on
The law provides for collection of a surcharge from exposed individuals and answering questions and
consumers at the point of purchase to fund recycling. concerns raised during the review process was issued
It also requires manufacturers to eliminate certain in 2003. These investigations are ongoing, but a more
hazardous ingredients from electronics sold in recent report has not yet been released by the EPA or
California. the U.S. Nuclear Regulatory Commission (NRC).

New technical guidelines are also being developed A report in the April 3, 2003, American Metal Market,
with the Basel Convention to address concerns that indicates that a last minute amendment was added to
some developing countries lack facilities to cope with the House Energy Policy Act of 2003 that could
piles of plastic wastes of all kinds. The recycling of prevent radioactive scrap metals from being released
wire and cable is getting special attention from the into the commerce stream. While release of
group. It is unclear how vigorously developing nations contaminated scrap is currently under a moratorium,
would enforce any burning ban, or whether it would metals interests have been lobbying for a more
cause more recycled wire to remain in the United permanent solution. The Metals Industries Recycling
States. Some researchers claim the burning of PVC Coalition (MIRC) urged support of the provision. MIRC
plastics produces persistent organic pollutants that felt that residual radioactive contamination in scrap
circulate globally. The Basel delegates have adopted metal imposed significant costs on metals producers
a set of technical guidelines for burning of certain in detection processes and in costly plant shutdowns
types of plastic, according to the Environmental News and cleanup, if an undetected source was accidentally
Service (ENS). melted. MIRC’s position was that radioactively
contaminated scrap metal originating at impacted or
New European rules on recycling old cars will force restricted areas at NRC-licensed facilities must be
Britain’s scrap yards and dismantling companies to disposed of in a way that prevents the release of this
invest around $750 million on new tooling and scrap into the stream of commerce – whether by
equipment. Under the directive on so-called end-of-life requiring disposal at a licensed low-level radioactive
vehicles, scrap operators will need to remove all waste facility or at an appropriate solid-waste landfill,
fluids, glass and reusable metal and plastic parts from or by requiring that the metal be recycled for restricted
old cars before they are dismantled. The British use within the NRC’s licensing scheme.
Metals Recycling Association has warned that the
investment costs will be passed on to vehicle owners.
Some two million vehicles per year are scrapped or
dismantled in Britain.

59
Table 1. LME, COMEX and U.S. Refined, Scrap and Ingot Prices
(U.S. currency)
Market Prices U.S. Buying Prices
LME COMEX U.S. Producer Refiners Brass Mill Red Brass
PERIOD Grade A, Cash HG, 1st Pos. Price #2 Scrap #1 Scrap Turnings
cts/lb cts/lb cts/lb cts/lb cts/lb cts/lb
1981 79 79 84 64 75 57
1982 67 66 73 41 59 46
1983 72 72 77 58 68 46
1984 62 61 67 49 58 43
1985 64 61 67 48 57 40
1986 62 62 66 49 58 38
1987 81 78 82 63 73 55
1988 118 115 121 87 101 76
1989 129 127 131 100 116 59
1990 121 119 123 97 112 63
1991 106 106 109 89 102 61
1992 104 103 107 88 99 57
1993 87 85 92 70 81 45
1994 105 107 110 85 101 47
1995 133 135 138 104 123 63
1996 104 106 109 84 102 52
1997 103 104 107 82 100 51
1998 75 75 79 60 74 40
1999 71 72 76 58 71 38
2000 82 84 88 65 80 39
2001 72 73 77 59 70 41
2002 71 72 76 59 70 37
2003 81 81 85 70 80 39
2004 130 129 134 108 126 55
2005 167 168 174 137 153 61
2006 305 309 316 259 291 102
1
2007 323 323 329 262 296 105

Source: Metals Week, American Metal Market, ICSG Copper Bulletin, U. S. Geol. Survey Min. Ind. Survey and Compendium.
1
Scrap prices are based on 10 months average of 2007. Refined prices are full year averages

Statistical Information 60
Table 2A. World Copper Recovery from All Sources1
(thousand metric tons)
Western Middle East Total Percent
Year Europe Africa and Asia America Oceania World Scrap
1969 2,271 860 1,152 3,844 162 8,904 38
1970 2,173 670 1,252 3,861 162 8,845 37
1971 2,173 803 1,237 3,653 202 8,876 36
1972 2,242 894 1,359 4,047 208 9,676 34
1973 2,488 930 1,574 4,007 204 10,210 35
1974 2,400 1,025 1,695 4,029 220 10,438 34
1975 2,196 941 1,464 3,462 214 9,430 30
1976 2,385 1,001 1,638 3,827 213 10,252 32
1977 2,358 987 1,735 3,969 218 10,523 31
1978 2,316 933 1,811 4,225 213 10,833 33
1979 2,300 897 1,909 4,686 214 11,361 36
1980 2,456 952 2,058 4,375 209 11,457 36
1981 2,462 918 2,259 4,590 240 11,856 35
1982 2,432 969 2,258 4,029 224 11,328 34
1983 2,477 1,040 2,419 3,969 245 11,631 34
1984 2,504 1,023 2,421 4,141 245 11,953 34
1985 2,564 976 2,530 4,122 235 12,108 35
1986 2,659 963 2,718 4,163 223 12,655 33
1987 2,636 921 2,837 4,419 258 13,042 35
1988 2,651 908 3,028 4,803 263 13,541 35
1989 2,691 892 3,054 5,021 296 13,868 35
1990 2,665 809 3,112 5,223 314 13,863 36
1991 2,653 713 3,227 5,220 313 13,721 36
1992 2,895 707 3,816 5,522 328 14,752 38
1993 2,905 635 4,043 5,674 343 15,028 38
1994 3,028 562 4,087 5,804 365 15,255 39
1995 3,256 530 4,700 6,090 291 16,308 40
1996 3,310 535 4,850 6,450 332 16,977 37
1997 3,554 507 4,775 7,143 292 17,876 36
1998 3,443 460 4,874 7,565 302 18,263 34
1999 3,352 423 5,285 7,571 444 18,922 34
2000 3,480 365 5,761 7,315 512 19,365 35
2001 3,361 416 5,819 7,484 582 19,712 30
2002 3,373 450 5,785 7,041 565 19,256 30
2003 3,270 454 5,940 6,674 506 18,863 29
2004 3,202 508 6,885 6,786 512 20,083 31
2005 3,061 509 7,727 6,722 483 20,687 30
2006 3,194 529 8,832 6,726 454 22,001 33
2007 3,266 591 9,077 6,763 474 22,400 32

Data sources: International Copper Study Group, USGS, USBM.

1
Includes primary and secondary copper production in refined and direct melt scrap.

61 Statistical Information
Table 2B. World Production of Refined Copper by Source
(thousand metric tons and percent of total)
Percent
Year Primary Secondary SX-EW Total Secondary
Refined Refined Refined Refined Refined
1969 5,093 1,127 22 6,242 18
1970 5,071 1,199 33 6,302 19
1971 5,189 1,027 33 6,249 16
1972 5,827 1,046 28 6,902 15
1973 6,019 1,107 37 7,164 15
1974 6,270 1,193 31 7,494 16
1975 5,965 912 36 6,914 13
1976 6,334 1,018 78 7,430 14
1977 6,536 1,073 112 7,722 14
1978 6,507 1,202 124 7,832 15
1979 6,413 1,340 263 8,016 17
1980 6,368 1,371 286 8,025 17
1981 6,721 1,336 334 8,391 16
1982 6,453 1,337 318 8,109 16
1983 6,672 1,367 300 8,339 16
1984 6,741 1,240 317 8,298 15
1985 6,768 1,449 213 8,430 17
1986 7,066 1,323 279 8,669 15
1987 7,023 1,494 332 8,850 17
1988 8,335 1,773 431 10,539 17
1989 8,454 1,943 543 10,939 18
1990 8,197 1,960 660 10,817 18
1991 8,064 1,947 689 10,700 18
1992 8,352 1,963 754 11,069 18
1993 8,628 1,892 763 11,283 17
1994 8,483 1,820 830 11,133 16
1995 8,685 2,113 1,069 11,867 18
1996 9,241 1,997 1,463 12,701 16
1997 9,645 2,122 1,759 13,526 16
1998 10,015 2,067 2,005 14,087 15
1999 10,130 2,104 2,316 14,550 14
2000 10,312 2,125 2,325 14,762 14
2001 11,122 1,892 2,599 15,638 12
2002 10,790 1,898 2,649 15,334 12
2003 10,741 1,792 2,723 15,256 12
2004 11,133 2,077 2,706 15,915 13
2005 11,717 2,177 2,694 16,588 13
2006 11,925 2,601 2,827 17,377 15
2007 e 12,233 2,758 3,040 18,031 15

Data Source: International Copper Study Group.

e
Estimated

Statistical Information 62
Table 2C. World Consumption of Copper in Direct Melt Scrap1
(thousand metric tons, copper content)

Year United States 2

Europe Africa Asia America Oceania World Total 1,000 tons % of World
1969 914 10 352 834 42 2,152 778 36
1979 940 22 423 1,134 40 2,559 1,054 41
1971 835 15 362 800 40 2,052 725 35
1972 856 16 374 879 34 2,159 796 37
1973 1,037 23 432 848 45 2,384 769 32
1974 869 25 456 863 46 2,259 769 34
1975 748 22 371 634 36 1,811 569 31
1976 891 20 380 770 37 2,098 699 33
1977 819 16 378 808 35 2,056 736 36
1978 895 18 386 899 34 2,232 827 37
1979 940 22 423 1,134 40 2,559 1,054 41
1980 1,055 31 491 1,010 44 2,632 922 35
1981 1,006 32 578 991 49 2,656 925 35
1982 941 32 579 803 46 2,402 720 30
1983 960 31 643 746 42 2,423 682 28
1984 1,012 41 675 889 48 2,664 813 31
1985 1,035 43 704 840 41 2,662 767 29
1986 1,100 37 785 792 38 2,752 721 26
1987 1,121 38 825 874 50 2,907 799 27
1988 1,033 39 986 933 40 3,031 860 28
1989 1,051 41 898 925 41 2,956 828 28
1990 1,016 38 992 985 40 3,071 870 28
1991 1,097 36 984 895 34 3,046 783 26
1992 1,308 35 1,367 976 25 3,712 844 23
1993 1,261 37 1,464 980 25 3,768 832 22
1994 1,420 32 1,573 1,097 25 4,146 936 23
1995 1,608 34 1,755 1,042 25 4,463 965 22
1996 1,463 16 1,773 1,030 21 4,303 975 23
1997 1,623 16 1,582 1,138 22 4,381 1,068 24
1998 1,564 17 1,476 1,127 17 4,200 1,073 26
1999 1,573 16 1,616 1,144 25 4,374 1,102 25
2000 1,685 15 1,651 1,228 25 4,603 1,102 24
2001 1,540 0 1,470 1,097 22 4,129 977 24
2002 1,481 0 1,303 1,114 22 3,920 960 24
2003 1,485 0 1,125 975 22 3,607 891 25
2004 1,435 0 1,707 1,003 22 4,167 914 22
2005 1,242 0 1,867 977 14 4,099 904 22
2006 1,316 0 2,241 1,065 25 4,647 909 20
2007 e 1,383 0 1,907 1,074 5 4,369 912 21

Data sources: International Copper Study Group, U.S. Bureau of Mines, U.S. Geological Survey.
1
Reported for some countries, such as the United States, but estimated for others based on semis production.
2
Revised to include copper from other than copper-base scrap.
e
Estimated on 9 months data.

63 Statistical Information
Table 2D. World Recovery of Copper from Copper-base Scrap, by Country and Area
(thousand metric tons, copper content)

Copper From Direct Melt and Refined Scrap Percent of World Copper Scrap
Year Western Middle Rest of Western
Europe America East & Asia Oceania World World Europe America Asia Oceania
1969 1414 1293 469 62 188 3364 42 38 14 2
1970 1405 1211 482 58 192 3290 43 37 15 2
1971 1302 1171 476 75 229 3178 41 37 15 2
1972 1300 1285 490 69 237 3313 39 39 15 2
1973 1481 1299 584 59 240 3605 41 36 16 2
1974 1366 1339 603 58 261 3569 38 38 17 2
1975 1153 970 475 48 246 2844 41 34 17 2
1976 1319 1140 527 52 259 3244 41 35 16 2
1977 1263 1194 522 66 281 3261 39 37 16 2
1978 1311 1361 589 60 306 3567 37 38 17 2
1979 1362 1685 663 76 324 4034 34 42 16 2
1980 1512 1582 723 65 321 4138 37 38 17 2
1981 1436 1517 835 76 340 4128 35 37 20 2
1982 1382 1303 837 64 355 3877 36 34 22 2
1983 1436 1202 922 76 370 3929 37 31 23 2
1984 1485 1248 932 74 379 4045 37 31 23 2
1985 1611 1282 981 72 371 4245 38 30 23 2
1986 1522 1251 1048 59 388 4210 36 30 25 1
1987 1674 1357 1099 79 408 4538 37 30 24 2
1988 1631 1458 1329 67 370 4787 34 30 28 1
1989 1693 1480 1308 76 401 4882 35 30 27 2
1990 1717 1519 1414 64 366 5015 34 30 28 1
1991 1831 1409 1382 69 355 4977 37 28 28 1
1992 2014 1546 1815 57 282 5658 36 27 32 1
1993 2021 1513 1857 49 258 5648 36 27 33 1
1994 2129 1581 1998 49 245 5953 36 27 34 1
1995 2386 1540 2398 43 241 6564 36 23 37 1
1996 2211 1500 2359 21 218 6287 35 24 38 0
1997 2476 1687 2113 22 214 6490 38 26 33 0
1998 2380 1624 2012 17 239 6255 38 26 32 0
1999 2376 1532 2138 25 431 6476 37 24 33 0
2000 2482 1574 2213 25 459 6728 37 23 33 0
2001 2186 1381 1971 22 453 5991 36 23 33 0
2002 2213 1257 1986 22 361 5817 38 22 34 0
2003 2160 1108 1819 22 312 5399 40 21 34 0
2004 2145 1139 2570 22 391 6244 34 18 41 0
2005 1941 1106 2856 14 374 6277 31 18 45 0
2006 2022 1200 3543 25 483 7249 28 17 49 0
2007 e 2140 1213 3338 5 436 7126 30 17 47 0

Data Sources: ICSG, USBM, U.S. Geological Survey.

e
Estimated on 9 months data.

Statistical Information 64
Table 3. World Copper and Copper Alloy Scrap Exports
(thousand metric tons, gross weight)

2000 2001 2002 2003 2004 2005 2006 2007 e

Australia 35 32 57 59 54 87 51 44
Austria 20 17 25 24 34 33 40 38
Belgium 153 137 127 152 169 178 162 180
Canada 73 70 71 70 81 120 165 158
Chile 4 8 18 25 38 37 55 92
China 10 10 8 8 9 6 7 6
Czech Rep. 37 40 38 37 53 54 57 56
Denmark 39 40 37 42 38 26 26 26
Finland 14 14 16 20 24 31 31 30
France 203 190 192 180 243 262 283 280
Germany 290 261 300 364 374 476 465 483
Greece 6 7 7 10 9 15 17 15
Hong Kong 149 130 99 337 340 121 130 152
Ireland 12 9 9 18 16 13 14 14
Italy 66 56 47 53 99 113 102 112
Japan 110 157 238 307 329 424 472 420
Kazakhstan 59 16 3 2 2 2 6 9
Malaysia 31 20 32 47 0 75 36 29
Mexico 72 71 60 76 173 105 126 124
Netherlands 140 101 149 125 106 182 223 242
Norway 17 17 16 17 21 23 24 24
Peru 2 2 2 2 2 2 5 7
Philippines 29 22 24 20 21 15 26 20
Poland 26 22 22 41 43 48 55 57
Portugal 20 14 19 25 36 35 30 22
Rep. of Korea 34 30 35 94 167 161 202 230
Russian Fed. 19 8 5 2 2 2 4 3
Singapore 60 56 66 56 50 43 35 34
Slovakia 8 6 8 9 12 15 19 22
South Africa 58 82 75 40 36 51 80 80
Spain 54 52 72 64 79 100 81 84
Sweden 31 29 35 36 44 44 46 51
Switzerland 62 58 55 56 69 75 74 76
Taiwan 75 50 45 76 61 107 125 138
Thailand 18 27 22 55 46 51 60 109
United Kingdom 173 156 165 211 243 235 310 295
United States 489 534 511 689 714 665 804 892
Other Countries 427 270 295 329 424 429 220 346
World Total 3,124 2,818 3,004 3,775 4,259 4,459 4,667 5,000

Source: International Copper Study Group, Dec. 2007.

e
Estimated on partial-year data (Jan.-Aug.).

65 Statistical Information
Table 4. World Copper and Copper Alloy Scrap Imports
(thousand metric tons, gross weight)

2001 2002 2003 2004 2005 2006 2007 e

Australia 3 3 3 4 2 2 11
Austria 59 83 57 72 83 89 91
Belgium 244 257 226 257 258 298 335
Brazil 4 1 0 0 2 1 1
Canada 91 42 37 55 48 56 52
China 3,335 3,080 3,162 3,957 4,821 4,943 5,350
Czech Rep. 3 2 2 6 6 8 9
Denmark 15 12 16 18 14 8 0
Finland 3 3 3 2 2 4 1
France 71 65 70 79 75 97 88
Germany 391 427 380 427 486 552 600
Greece 3 3 2 2 1 2 6
Hong Kong 92 74 111 107 123 147 195
Hungary 5 4 1 1 1 1 1
India 111 93 92 110 150 105 120
Indonesia 4 3 3 3 13 2 1
Ireland 1 1 1 0 0 0 0
Italy 169 188 165 131 125 214 180
Japan 143 126 122 145 103 121 135
Malaysia 32 10 22 26 24 13 12
Mexico 7 0 9 20 14 18 5
Netherlands 65 71 80 90 77 111 109
New Zealand 3 1 0 0 1 0 0
Norway 8 8 11 11 12 13 15
Poland 4 5 6 15 6 5 14
Portugal 1 1 2 2 3 6 8
Rep. of Korea 177 196 153 205 206 205 193
Singapore 18 27 19 21 16 18 6
Slovakia 6 6 8 20 20 18 16
South Africa 5 4 3 3 2 2 2
Spain 86 84 58 115 85 87 56
Sweden 31 44 52 77 51 56 76
Switzerland 14 8 10 12 10 8 9
Taiwan 61 92 81 121 112 146 128
Turkey 6 7 30 35 10 1 1
United Kingdom 20 19 18 15 41 20 24
United States 115 100 91 102 114 118 124
Other countries 37 98 78 96 69 26 50
World 5,438 5,247 5,182 6,359 7,187 7,518 7,012

Source: International Copper Study Group, Nov. 2006, and U.S. Geological Survey.
e
Estimated on partial year data (8 months).

Statistical Information 66
Table 5. World Production of Copper and Copper Alloy Ingots1
(thousand metric tons)
1998 1999 2000 2001 2002 2003 2004 2005 2006
Austria 3.5 3.2 3.3 2.5 1.8 2.0 2.2 2.5 2.6
Denmark 0.2 0.2 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Finland 2.4 2.3 1.9 1.2 0.8 0.0 0.0 0.0 0.0
France 11.7 12.4 13.3 12.5 12.5 12.3 13.0 11.4 12.5
Germany 58.5 56.1 62.6 63.4 56.1 43.7 44.1 53.6 57.2
Italy 117.1 116.4 116.1 112.0 103.3 96.5 95.0 89.0 91.8
Japan 82.2 83.9 86.4 87.9 86.6 90.0 86.2 85.4 89.7
Kazakhstan 0.0 2.3 1.0 0.8 1.1 1.6 0.0 0.0 0.0
Mexico 70.5 61.4 56.9 50.9 52.0 52.8 0.0 0.0 0.0
Netherlands 2.6 2.6 2.6 2.4 2.3 2.4 2.4 2.6 2.7
Poland 25.9 24.1 21.5 16.0 13.6 14.4 13.4 12.1 11.2
Portugal 1.8 1.9 1.5 3.1 4.5 5.3 6.0 6.7 6.8
Romania 0.0 0.0 0.0 0.0 2.9 3.7 2.7 2.2 0.0
Spain 12.3 12.5 14.0 13.8 13.3 15.5 16.8 15.6 16.7
Scandinavia 14.9 13.8 13.6 12.0 11.0 9.3 9.0 8.7 8.7
Turkey 0.0 0.0 0.0 0.0 0.0 0.0 11.4 18.5 17.5
United Kingdom 42.1 38.1 34.0 37.5 34.5 32.5 34.5 27.0 22.8
United States 157.8 152.8 160.8 145.8 123.1 114.0 122.1 122.3 120.3
World 607.6 585.0 588.3 559.8 517.5 494.4 458.8 457.6 460.5

Europe 297.1 286.9 284.2 275.2 255.8 237.6 239.1 231.4 233.0
Mid East & Asia 82.2 83.9 86.4 87.9 86.6 90.0 97.6 103.9 107.2
America 228.3 214.2 217.7 196.7 175.1 166.8 122.1 122.3 120.3

Data Source: International Copper Study Group. United States - USGS Mineral Yearbook, var. issues.
1
Master alloys not included.

67 Statistical Information
Table 5A. World Copper Alloy Foundry Production
(thousand metric tons, gross weight)
1998 1999 2000 2001 2002 2003 2004 2005 2006
Argentina 0.0 0.0 0.0 0.0 2.9 3.4 3.9 0.0 0.0
Austria 3.5 3.3 3.4 3.2 3.3 3.4 3.3 5.5 2.7
Belgium 0.6 0.7 0.6 0.5 0.5 0.5 0.5 0.5 1.0
Brazil 20.1 15.7 15.3 14.1 13.7 0.0 19.5 19.0 20.3
Canada 11.1 12.0 0.0 0.0 0.0 0.0 18.6 18.6 18.6
China 95.1 107.9 119.9 125.0 137.2 157.0 327.6 416.1 470.2
Croatia 1.3 0.7 0.6 0.7 0.6 0.7 0.7 1.1 0.8
Czech Rep. 3.5 2.9 2.0 1.5 1.8 1.5 1.1 1.7 1.8
Denmark 1.7 1.5 1.3 1.1 1.3 1.6 1.3 1.1 0.8
Finland 4.8 4.3 3.8 3.8 3.9 3.8 4.0 4.0 4.3
France 24.6 24.1 25.3 25.9 29.4 28.3 27.2 26.3 25.5
Germany 84.7 84.5 91.2 88.5 90.0 91.3 88.5 84.4 98.1
Hungary 2.5 2.9 3.1 2.7 2.3 1.9 2.1 2.1 4.3
Iran 0.0 0.0 0.0 25.0 0.0 27.0 0.0 0.0 0.0
Italy 126.8 124.5 123.7 114.5 110.0 106.1 97.8 83.0 92.0
Japan 85.5 82.7 87.1 86.6 86.7 100.6 105.8 98.1 97.8
Rep. Of Korea 18.0 18.5 19.6 20.8 21.6 22.2 22.9 23.2 23.6
Mexico 124.8 124.8 135.0 80.0 175.0 175.0 180.0 180.0 0.0
Netherlands 2.6 2.5 2.4 2.8 2.7 2.5 2.4 1.9 0.0
Norway 3.3 3.0 3.4 3.4 3.5 2.6 2.7 4.7 5.3
Poland 20.1 21.0 20.5 17.2 16.8 6.3 7.4 6.3 7.3
Portugal 1.6 4.0 4.7 6.0 6.6 6.0 7.8 8.7 10.8
Romania 9.0 9.6 9.7 9.8 10.0 10.0 4.1 2.7 3.4
Russian Fed. 0.0 0.0 0.0 0.0 0.0 0.0 0.0 160.0 160.0
Slovenia 2.4 3.4 3.4 3.4 3.5 3.0 0.0 6.7 0.0
South Africa 0.0 4.0 5.0 0.0 0.0 14.5 14.9 14.9 3.0
Spain 13.0 13.5 16.1 13.1 13.0 6.3 7.9 7.9 9.1
Sweden 10.6 10.3 10.1 10.6 10.0 10.9 12.0 11.2 11.9
Switzerland 2.8 2.8 2.9 2.5 2.3 2.4 3.0 2.7 3.1
Taiwan 49.1 48.0 50.0 50.0 49.0 46.4 41.8 42.0 40.9
Thailand 0.0 0.0 0.0 0.0 0.0 0.0 0.0 28.6 28.6
Turkey 0.6 0.9 1.3 2.8 2.1 2.8 8.5 16.0 17.5
Ukraine 0.0 8.0 10.0 21.0 11.0 0.0 11.0 11.0 11.0
United Kingdom 23.7 29.6 25.0 25.5 20.5 15.0 15.7 15.0 13.0
United States 1 224.2 258.1 278.3 252.5 254.1 246.0 235.3 234.5 206.6
World 973.9 1032.4 1076.9 1017.0 1087.6 1102.6 1282.4 1542.2 1395.5

Europe 345.4 359.8 365.40 360.20 345.30 307.70 303.60 451.20 468.40
Mid East & Asia 248.3 258 277.90 310.20 296.60 356.00 506.60 624.00 678.60
America 380.219 410.6 428.60 346.55 445.73 424.39 457.29 452.13 245.46

Data source: International Copper Study Group Bulletin, Table 18. February 2008.
1
United States data represent consumption of refined copper, brass ingot and copper scrap by foundries and miscellaneous manufacturers.
Source: USGS Minerals Yearbook, Table 12.

Statistical Information 68
Table 5B. World Copper, Copper Alloy and Master Alloy Ingot Imports1 (thousand metric tons)
2001 2002 2003 2004 2005 2006 2007 e
Australia 4.0 4.4 4.1 3.9 2.9 3.8 3.0
Austria 3.0 2.3 3.0 2.4 2.0 2.4 2.5
Canada 8.8 7.7 7.1 14.9 14.4 12.4 11.3
China 27.9 43.4 82.0 66.5 63.6 46.0 58.0
Finland 3.9 3.8 4.3 2.8 3.2 3.2 3.3
France 13.0 13.7 8.3 7.6 10.1 11.0 19.8
Germany 35.8 26.8 38.4 24.1 28.8 29.0 46.6
Hong Kong 5.7 6.9 7.2 10.5 7.6 7.3 4.9
India 1.5 1.4 3.7 6.7 6.3 3.4 2.6
Italy 21.6 19.8 22.0 16.7 8.1 14.3 26.6
Mexico 6.3 9.1 9.5 7.0 6.3 6.8 5.2
Poland 1.6 1.2 1.8 2.1 3.2 3.7 4.4
Portugal 3.5 4.4 5.2 6.0 4.5 5.6 4.8
Rep. Of Korea 1.2 0.6 5.3 2.7 0.9 3.7 10.6
Singapore 3.1 5.4 5.8 22.7 10.0 12.1 10.0
Spain 6.5 7.3 4.2 5.8 4.4 5.5 6.2
Sweden 3.8 4.6 2.9 2.8 3.0 4.3 8.6
Taiwan 12.3 11.2 19.6 12.6 9.6 13.9 9.7
Thailand 8.5 8.8 11.8 11.7 10.6 9.9 8.5
Turkey 0.3 1.1 3.8 4.7 3.8 2.8 0.7
United Kingdom 6.9 5.1 6.2 8.1 6.2 6.8 6.6
United States 7.0 5.3 4.0 6.0 5.8 10.2 9.1
Rest of World 41.3 33.0 38.9 37.2 35.4 37.6 27.0
World 227.6 227.5 299.4 285.6 250.6 255.7 290.0
1
Data includes both copper alloy and master alloy ingots. Source: ICSG Monthly Bulletin, Dec. 2007.
e
Estimated on 8 months data.

Table 5C. World Copper, Copper Alloy and Master Alloy Ingot Exports1 (thousand metric tons)
2002 2003 2004 2005 2006 2007 e
Australia 3.2 6.6 4.1 4.6 5.0 9.7
Belgium 15.1 21.6 13.6 14.5 1.1 11.7
Canada 3.1 2.6 3.5 3.5 7.5 6.1
France 9.3 6.6 11.9 9.9 9.6 14.0
Germany 26.9 21.5 21.0 21.0 20.2 23.0
Hong Kong 7.5 8.8 13.1 11.1 10.8 10.0
Italy 12.6 12.2 17.0 14.2 13.5 25.0
India 0.8 7.1 9.6 12.4 11.1 11.0
Japan 28.2 31.1 25.0 29.9 33.9 32.0
Netherlands 6.0 5.3 3.6 3.0 5.7 6.8
Poland 5.1 5.3 5.0 6.2 6.1 6.6
Rep. of Korea 9.4 13.8 19.2 20.2 19.6 18.3
Russian Fed. 9.8 12.3 6.4 7.8 1.3 3.7
Singapore 2.5 4.4 5.5 8.1 9.8 5.6
South Africa 8.4 4.6 6.0 5.0 4.6 5.0
Spain 7.1 9.8 11.7 9.8 9.7 15.0
Sweden 6.5 7.1 5.0 5.2 6.5 13.4
Switzerland 0.8 1.0 0.8 0.9 0.8 0.8
Taiwan 5.0 6.7 9.7 7.3 10.1 9.0
Turkey 2.7 2.9 7.3 2.2 2.0 2.0
United Kingdom 26.2 24.1 22.0 15.0 17.3 19.0
United States 27.6 27.5 33.7 35.4 40.1 38.0
Rest of World 31.6 45.1 48.1 69.1 64.3 64.2
World Total 255.5 287.7 303.1 316.2 310.2 350.0
1
Data includes both copper alloy and master alloy ingots. Source: ICSG Monthly Bulletin, Dec. 2007.
e
Estimated on 8 months data.

69 Statistical Information
Table 6. U.S. and World Refined Copper Consumption and U.S. Copper from Scrap
(metric tons, copper)
U.S. Copper Consumption and Copper Base Scrap Statistics
World U.S. Refined Percent Scrap Copper in Percent Percent Cu in Total Apparent Total Percent Percent new
Year Refined Copper (Reported) in U.S. Refined Old U.S. Old in All New in All U.S. Consumption all scrap in scrap in U.S.
Consumption Consumption Consumption Scrap Scrap Scrap Scrap 1 including all scrap Consumption Consumption
1923 1,217,512 878,480 15 245,756 66 34 372,928 981,615 38 13
1924 1,371,864 740,046 17 241,493 69 31 352,407 995,312 35 11
1925 1,518,628 782,278 21 264,000 69 31 381,211 1,041,316 37 11
1926 1,566,708 968,027 19 305,994 70 30 435,229 1,167,748 37 11
1927 1,594,831 854,316 21 307,899 69 31 444,628 1,116,661 40 12
1928 1,822,535 970,672 21 331,576 68 32 486,430 1,248,403 39 12
1929 1,891,481 1,113,502 24 366,866 65 35 568,301 1,411,837 40 14
1930 1,544,915 829,923 27 310,439 73 27 423,629 1,031,513 41 11
1931 1,282,760 606,710 28 237,047 75 25 314,593 750,447 42 10
1932 988,832 375,729 34 164,110 73 27 225,042 473,297 48 13
1933 1,129,445 490,061 36 236,140 77 23 306,820 621,799 49 11
1934 1,361,685 501,525 40 282,044 82 18 342,372 466,666 73 13
1935 1,644,726 658,254 37 328,129 81 19 407,235 826,823 49 10
1936 1,894,202 845,422 28 347,180 79 21 439,622 1,089,577 40 8
1937 2,184,501 903,404 29 370,948 77 23 482,713 1,113,823 43 10
1938 1,972,220 557,092 31 242,491 74 26 326,405 724,796 45 12
1939 2,284,000 807,314 17 260,271 57 43 453,320 1,146,197 40 17
1940 2,598,000 1,088,866 14 302,899 63 37 482,664 1,432,065 34 13
1941 2,634,465 1,615,487 7 374,394 57 43 658,976 2,246,440 29 13
1942 2,766,000 1,622,954 6 387,479 46 54 841,645 2,215,083 38 21
1943 2,756,000 1,590,733 8 387,841 39 61 985,246 2,354,212 42 25
1944 2,585,000 1,568,179 6 414,321 48 52 862,680 2,181,230 40 21
1945 2,211,717 1,251,255 7 450,957 49 51 913,096 2,104,915 43 22
1946 2,113,741 1,029,835 10 368,728 51 49 728,965 2,074,492 35 17
1947 2,575,498 1,327,478 19 456,655 52 48 872,477 2,029,686 43 20
1948 2,577,313 1,288,732 18 458,549 52 48 882,499 2,028,404 44 21
1949 2,335,094 1,024,834 20 347,949 54 46 646,953 1,632,216 40 18
1950 2,700,690 1,292,225 15 440,176 50 50 886,537 1,783,590 50 25
1951 2,887,570 1,285,359 11 415,603 49 51 845,752 1,972,350 43 22
1952 2,963,773 1,342,391 10 376,151 46 54 819,367 2,058,959 40 22
1953 2,902,992 1,355,529 14 389,534 45 55 869,504 2,043,751 43 23
1954 3,170,612 1,138,271 16 369,284 48 52 761,951 1,715,501 44 23
1955 3,586,102 1,362,596 16 466,823 52 48 897,210 2,076,394 43 21
1956 3,680,450 1,380,181 17 425,006 50 50 844,284 2,010,632 42 21
1957 3,691,336 1,226,627 18 403,237 53 47 763,747 1,812,288 42 20
1958 3,762,096 1,134,595 17 373,186 52 48 723,378 1,655,279 44 21
1959 4,099,569 1,327,240 17 427,291 51 49 844,199 1,963,605 43 21
1960 4,458,814 1,224,605 22 389,514 49 51 790,510 1,853,104 43 22
1961 4,629,365 1,327,057 19 372,953 48 52 770,145 1,914,387 40 21
1962 4,645,694 1,451,202 18 377,093 45 55 836,269 2,099,229 40 22
1963 4,981,353 1,582,378 23 382,690 43 57 883,985 2,213,412 40 23
1964 5,513,000 1,655,868 19 429,571 43 57 991,572 2,338,878 42 24
1965 5,709,000 1,818,564 22 465,781 41 59 1,136,930 2,652,724 43 25
1966 6,007,000 2,140,915 21 485,217 40 60 1,210,411 2,941,428 41 25
1967 5,762,000 1,755,940 21 437,861 42 58 1,052,250 2,449,960 43 25
1968 6,130,000 1,705,780 22 472,436 43 57 1,105,260 2,542,002 43 25
1969 6,678,000 1,943,388 23 521,531 42 58 1,247,827 2,785,198 45 26
1970 6,769,000 1,853,654 25 457,286 40 60 1,131,806 2,493,241 45 27

(table continued on next page)

Data Source: U.S. Bureau of Mines and U.S. Geological Survey Minerals Yearbooks.
World consumption series from International Copper Study Group.
1
Includes copper from other than copper-base scrap.

Statistical Information 70
Table 6. (continued) U.S. and World Refined Copper Consumption and U.S. Copper from Scrap
(metric tons, copper)
U.S. Copper Consumption and Copper Base Scrap Statistics
World U.S. Refined Percent Scrap Copper in Percent Percent Cu in Total Apparent Total Percent Percent new
Year Refined Copper (Reported) in U.S. Refined Old U.S. Old in All New in All U.S. Consumption all scrap in scrap in U.S.
Consumption Consumption Consumption Scrap Scrap Scrap Scrap 1 including all scrap Consumption Consumption
1971 6,700,000 1,832,066 20 403,812 37 63 1,088,731 2,569,568 42 27
1972 7,322,000 2,031,067 19 415,667 35 65 1,180,223 2,904,989 41 26
1973 8,106,000 2,210,853 19 441,086 35 65 1,249,336 3,031,528 41 27
1974 7,702,000 1,990,516 23 438,562 36 64 1,219,547 2,916,312 42 27
1975 6,780,000 1,392,083 22 334,908 38 62 881,752 2,019,655 44 27
1976 7,939,000 1,807,008 19 380,225 37 63 1,038,975 2,582,858 40 26
1977 8,495,000 1,982,162 18 409,928 38 62 1,085,425 2,759,205 39 24
1978 8,913,000 2,189,301 19 501,650 40 60 1,247,235 3,123,572 40 24
1979 9,250,000 2,158,442 23 604,301 39 61 1,552,525 3,382,365 46 28
1980 9,045,000 1,862,096 28 613,458 43 57 1,437,427 3,003,074 48 27
1981 9,153,000 2,025,169 24 591,805 42 58 1,407,397 3,086,642 46 26
1982 8,534,000 1,658,142 28 517,726 44 56 1,187,466 2,432,125 49 28
1983 8,699,000 1,803,929 22 449,478 41 59 1,083,579 2,671,594 41 24
1984 9,578,000 2,122,734 14 460,695 41 59 1,119,914 2,771,277 40 24
1985 9,353,000 1,976,101 19 503,407 44 56 1,139,084 2,780,111 41 23
1986 9,794,000 2,097,351 19 477,469 42 58 1,126,528 2,785,041 40 23
1987 10,053,000 2,127,178 19 497,937 41 59 1,214,059 2,913,002 42 25
1988 10,521,000 2,210,424 20 518,179 40 60 1,306,891 3,003,881 44 26
1989 10,988,000 2,203,116 22 547,561 42 58 1,308,455 2,945,257 44 26
1990 10,849,000 2,150,426 20 535,656 41 59 1,309,529 2,942,053 45 26
1991 10,757,000 2,057,824 20 518,000 43 57 1,200,690 2,765,237 43 25
1992 11,164,000 2,178,191 20 555,000 43 57 1,277,077 3,027,320 42 24
1993 10,987,200 2,367,930 19 543,000 42 58 1,285,695 3,256,313 39 23
1994 11,552,900 2,680,200 15 500,000 38 62 1,327,897 3,512,297 38 24
1995 12,052,200 2,534,371 14 442,509 34 66 1,316,795 3,411,795 39 26
1996 12,549,600 2,613,472 13 428,362 32 68 1,319,152 3,718,252 35 24
1997 13,083,600 2,790,350 14 497,670 34 66 1,464,596 3,904,996 38 25
1998 13,468,100 2,888,600 12 465,894 33 67 1,422,223 3,941,118 36 24
1999 14,278,000 2,980,384 8 380,833 29 71 1,331,409 3,996,918 33 24
2000 15,130,000 3,022,654 7 358,392 27 73 1,310,000 4,099,105 32 23
2001 14,901,700 2,620,322 7 316,617 28 72 1,150,000 3,123,572 37 27
2002 15,230,800 2,365,194 3 208,219 20 80 1,029,622 3,298,121 31 25
2003 15,716,200 2,292,023 2 206,053 22 78 943,959 3,361,546 28 22
2004 16,846,100 2,414,333 2 191,210 20 80 965,094 3,431,396 28 23
2005 16,731,100 2,270,360 2 182,499 19 81 951,122 3,189,040 30 24
2006 17,122,300 2,130,300 2 148,300 16 84 933,040 3,045,085 31 26
2007 e 18,534,700 2,227,000 2 146,700 16 84 920,000 3,074,323 30 25

Data Source: U.S. Bureau of Mines and U.S. Geological Survey Minerals Yearbooks.
World consumption series from International Copper Study Group.
1
Includes copper from other than copper-base scrap.
e
Estimated on partial year data.

71 Statistical Information
Table 6A. U.S. Cumulative Copper Calculations, 1951–2007
(metric tons, copper content)
1 4
Annual Statistics Resource Calculations Cumulative U.S. Statistics
Year U.S. Apparent Copper Primary Cumulative Cum Resource Cumulative U.S. Percent All Cumulative U.S. Percent Old
Consumption 2 in Old Copper Primary US (less annual Consumption of Scrap Recovery of Plus Net Exports
3
Scrap Consumed Consumption new Scrap) old and new from Cum. Cu in Old Scrap from Cum. Primary
scrap, 1906-2007 Primary plus net exports less New Scrap
1951 1,542,201 415,603 1,126,598 31,351,764 27,114,885 19,227,342 61 11,295,707 41.7
1952 1,615,743 376,151 1,239,592 32,591,356 27,911,261 20,046,709 62 11,671,858 41.8
1953 1,563,781 389,534 1,174,247 33,765,603 28,605,538 20,916,213 62 12,061,392 42.2
1954 1,322,834 369,284 953,550 34,719,153 29,166,421 21,678,164 62 12,430,676 42.6
1955 1,626,799 466,823 1,159,976 35,879,129 29,915,218 22,575,374 63 12,897,499 43.1
1956 1,641,023 425,006 1,216,017 37,095,146 30,662,288 23,419,658 63 13,322,505 43.4
1957 1,451,195 403,237 1,047,958 38,143,104 31,350,319 24,183,405 63 13,725,742 43.8
1958 1,304,939 373,186 931,753 39,074,857 31,932,028 24,906,783 64 14,098,928 44.2
1959 1,547,231 427,291 1,119,940 40,194,797 32,634,526 25,750,982 64 14,526,219 44.5
1960 1,452,182 389,514 1,062,668 41,257,465 33,296,124 26,541,492 64 15,041,122 45.2
1961 1,517,154 372,953 1,144,201 42,401,666 34,043,174 27,311,637 64 15,528,785 45.6
1962 1,639,881 377,093 1,262,788 43,664,454 34,846,958 28,147,906 64 15,938,552 45.7
1963 1,712,345 382,690 1,329,655 44,994,109 35,675,090 29,031,891 65 16,355,766 45.8
1964 1,776,341 429,571 1,346,770 46,340,879 36,460,395 30,023,463 65 16,872,279 46.3
1965 1,981,932 465,781 1,516,151 47,857,030 37,305,040 31,160,393 65 17,388,022 46.6
1966 2,216,369 485,217 1,731,152 49,588,182 38,310,863 32,370,804 65 17,894,957 46.7
1967 1,835,788 437,861 1,397,927 50,986,109 39,094,184 33,423,054 66 18,378,479 47.0
1968 1,909,069 472,436 1,436,633 52,422,742 39,898,102 34,528,314 66 18,931,537 47.4
1969 2,058,319 521,531 1,536,788 53,959,530 40,709,177 35,776,141 66 19,509,294 47.9
1970 1,818,866 457,286 1,361,580 55,321,110 41,396,092 36,907,947 67 20,043,030 48.4
1971 1,886,418 403,812 1,482,606 56,803,716 42,192,010 37,996,678 67 20,496,343 48.6
1972 2,142,445 415,667 1,726,778 58,530,494 43,152,220 39,176,901 67 20,950,635 48.6
1973 2,223,351 441,086 1,782,265 60,312,759 44,126,162 40,426,237 67 21,470,476 48.7
1974 2,144,892 438,562 1,706,330 62,019,089 45,041,942 41,645,784 67 21,978,496 48.8
1975 1,473,444 334,908 1,138,536 63,157,625 45,633,001 42,527,536 67 22,394,379 49.1
1976 1,923,872 380,225 1,543,647 64,701,272 46,518,134 43,566,511 67 22,827,177 49.1
1977 2,069,701 409,928 1,659,773 66,361,045 47,516,417 44,651,936 67 23,293,894 49.0
1978 2,369,537 501,650 1,867,887 68,228,932 48,647,169 45,899,171 67 23,885,326 49.1
1979 2,434,234 604,301 1,829,933 70,058,865 49,528,785 47,451,696 68 24,590,717 49.6
1980 2,178,849 613,458 1,565,391 71,624,256 50,270,463 48,889,123 68 25,319,992 50.4
1981 2,271,416 591,805 1,679,611 73,303,867 51,134,116 50,296,520 69 25,989,194 50.8
1982 1,762,385 517,726 1,244,659 74,548,526 51,709,035 51,483,986 69 26,585,582 51.4
1983 2,012,739 449,478 1,563,261 76,111,787 52,662,949 52,567,565 69 27,101,892 51.5
1984 2,116,058 460,695 1,655,363 77,767,150 53,655,093 53,687,479 69 27,679,845 51.6
1985 2,144,436 503,407 1,641,029 79,408,179 54,660,443 54,826,563 69 28,350,784 51.9
1986 2,138,223 477,469 1,660,754 81,068,933 55,669,897 55,953,091 69 29,004,126 52.1
1987 2,196,540 497,937 1,698,603 82,767,536 56,652,718 57,167,150 69 29,665,031 52.4
1988 2,213,768 518,179 1,695,589 84,463,125 57,560,996 58,474,041 69 30,359,678 52.7
1989 2,184,534 547,561 1,636,973 86,100,098 58,436,904 59,782,496 69 31,111,624 53.2
1990 2,168,179 535,656 1,632,523 87,732,621 59,295,555 61,092,025 70 31,800,027 53.6
1991 2,090,000 518,000 1,572,000 89,304,621 60,177,412 62,292,715 70 32,473,337 54.0
1992 2,300,000 555,000 1,745,000 91,049,621 61,205,578 63,569,792 70 33,098,069 54.1
1993 2,510,000 543,000 1,967,000 93,016,621 62,433,501 64,855,487 70 33,703,793 54.0
1994 2,690,000 500,000 2,190,000 95,206,621 63,790,004 66,183,384 70 34,358,907 53.9
1995 2,540,000 442,509 2,097,491 97,304,112 65,010,718 67,500,179 69 35,034,133 53.9
1996 2,830,000 428,362 2,401,638 99,705,750 66,519,028 68,819,331 69 35,608,661 53.5
1997 2,950,000 497,670 2,452,330 102,158,080 67,992,502 70,283,927 69 36,246,330 53.3
1998 3,027,355 465,894 2,561,461 104,719,541 69,555,373 71,706,150 68 36,831,273 53.0
1999 3,127,206 380,936 2,746,270 107,465,811 71,275,683 73,034,756 68 37,366,834 52.4
2000 3,090,537 358,392 2,732,145 110,197,956 73,105,750 74,347,756 67 38,026,342 52.0
2001 2,508,768 317,212 2,191,556 112,389,512 74,246,084 75,497,981 67 38,710,326 52.1
2002 2,610,866 190,135 2,420,731 114,810,243 75,673,696 76,528,203 67 39,247,783 51.9
2003 2,427,975 206,842 2,221,133 117,031,376 77,355,180 77,472,432 66 39,968,339 51.7
2004 2,554,431 191,210 2,363,221 119,394,597 79,047,600 78,437,526 66 40,684,629 51.5
2005 2,387,306 183,233 2,204,073 121,598,670 80,518,220 79,390,028 65 41,353,365 51.4
2006 2,183,174 141,113 2,042,061 123,640,731 81,732,894 80,358,528 65 42,092,785 51.5
2007e 2,305,638 146,700 2,158,938 125,799,669 83,071,972 81,325,088 65 42,871,553 51.6

1
Annual Statistics from U.S. Bureau of Mines, U.S. Geological Survey. 2 Consumption = primary refined production + old scrap + net imports + stock change
3
Primary copper = consumption less old scrap. 4 Series based on 1864-2007 data. e Estimated on partial year data.

Statistical Information 72
Table 6B. Estimation of the Recycling Input Ratio (RIR)1 and Recovery Ratio
for the United States2, 1981–2007 (thousand metric tons)

Brass & Wire Foundry Total Gross Weight Recycling Copper Scrap Total Scrap Recycling
Year Mill Production Semis Scrap3 Input Ratio Exports Recovered Recovery Ratio
Production (Percent) (Percent)4
1981 2784.2 312.8 3096.9 1825.6 58.9 146.2 1971.8 63.7
1982 2102.4 251.5 2353.9 1514.8 64.4 146.0 1660.8 70.6
1983 2278.4 229.3 2507.7 1381.6 55.1 128.2 1509.8 60.2
1984 2567.7 243.5 2811.2 1433.5 51.0 189.6 1623.1 57.7
1985 2401.3 264.1 2665.4 1411.8 53.0 280.2 1692.0 63.5
1986 1969.1 248.8 2218.0 1495.0 67.4 289.4 1784.4 80.5
1987 2783.8 243.3 3027.1 1578.6 52.1 293.8 1872.4 61.9
1988 2810.1 258.3 3068.4 1619.2 52.8 320.5 1939.7 63.2
1989 2776.4 251.0 3027.4 1620.6 53.5 367.5 1988.0 65.7
1990 2707.6 185.9 2893.5 1607.9 55.6 324.4 1932.3 66.8
1991 2623.0 214.3 2837.3 1553.0 54.7 306.6 1859.6 65.5
1992 2783.1 220.4 3003.5 1668.5 55.6 246.6 1915.2 63.8
1993 2998.9 214.5 3213.4 1696.7 52.8 262.1 1958.8 61.0
1994 3334.6 230.7 3565.3 1710.0 48.0 359.9 2069.9 58.1
1995 3297.2 225.3 3522.5 1652.5 46.9 456.2 2108.7 59.9
1996 3584.1 229.8 3813.9 1625.3 42.6 392.7 2018.0 52.9
1997 3721.9 237.2 3959.1 1755.7 44.3 379.6 2135.3 53.9
1998 3807.5 224.2 4031.7 1720.0 42.7 307.5 2027.5 50.3
1999 3926.2 258.1 4184.3 1630.0 39.0 314.7 1944.7 46.5
2000 3916.5 278.3 4194.8 1587.2 37.8 485.5 2072.7 49.4
2001 3306.2 252.5 3558.7 1376.8 38.7 534.0 1910.8 53.7
2002 3257.2 254.1 3511.3 1227.9 35.0 511.0 1738.8 49.5
2003 3075.4 246.0 3321.4 1113.9 33.5 689.0 1802.9 54.3
2004 3435.6 235.3 3670.9 1143.9 31.2 714.0 1857.9 50.6
2005 3214.5 234.5 3449.0 1148.1 33.3 657.0 1805.1 52.3
2006e 2975.8 206.6 3182.4 1150.1 36.1 798.2 1948.3 61.2
2007e 3100.0 232.0 3332.0 1067.6 32.0 728.0 1795.6 53.9

1
Recycling Input Ratio (RIR) = Total Scrap Consumed/Total Semis Produced methodology after ICSG Special Paper, 2004 ,
“Recycling in Western Europe” unpublished
2
Data sources: U. S. Dept of Commerce, U.S. Bureau of Mines, U. S. Geological Survey and International Copper Study Group publications.
3
Gross weight scrap consumed by U.S. brass mills, wire mills, foundries and miscellaneous manufacturers.
4
Recycling Recovery Ratio (ROR)= total scrap recovered/total semis produced.
e
Estimated

73 Statistical Information
Table 7. U.S. Production of Refined Copper, by Source
(thousand metric tons)

Percent
Year Primary Secondary SX-EW Total Secondary
Refined Refined Refined Refined Refined
1968 1,304 378 10 1,692 22
1969 1,581 453 22 2,056 22
1970 1,568 464 33 2,065 22
1971 1,411 363 33 1,808 20
1972 1,671 384 28 2,083 18
1973 1,658 422 37 2,117 20
1974 1,470 451 31 1,952 23
1975 1,268 313 36 1,617 19
1976 1,318 340 78 1,737 20
1977 1,254 350 104 1,707 20
1978 1,354 420 95 1,869 22
1979 1,419 498 97 2,015 25
1980 1,099 515 116 1,730 30
1981 1,385 483 159 2,027 24
1982 1,096 468 130 1,694 28
1983 1,080 402 102 1,584 25
1984 1,074 307 100 1,481 21
1985 967 372 90 1,429 26
1986 949 406 125 1,480 27
1987 968 415 159 1,542 27
1988 1,178 446 228 1,853 24
1989 1,165 480 312 1,957 25
1990 1,183 441 394 2,017 22
1991 1,136 418 441 1,995 21
1992 1,209 433 502 2,144 20
1993 1,302 460 491 2,253 20
1994 1,346 392 493 2,230 18
1995 1,390 352 539 2,282 15
1996 1,434 333 574 2,341 14
1997 1,484 380 587 2,451 16
1998 1,531 349 609 2,489 14
1999 1,303 243 586 2,132 11
2000 1,028 209 557 1,794 12
2001 1,000 172 628 1,801 10
2002 841 70 601 1,512 5
2003 662 53 591 1,307 4
2004 671 51 584 1,306 4
2005 654 47 554 1,255 4
2006 675 45 530 1,250 4
2007 e 760 42 518 1,320 3

Data Source: U.S. Bureau of Mines and U.S. Geological Survey.

e
Estimated on partial year data.

Statistical Information 74
Table 8. U.S. Exports and Imports of Copper and Copper Alloy Scrap
(metric tons)
UNALLOYED SCRAP COPPER ALLOY COPPER ALLOY TOTAL COPPER TOTAL COPPER COPPER ALLOY COPPER ALLOY UNALLOYED TOTAL COPPER TOTAL COPPER
YEAR IMPORTS SCRAP IMPORTS SCRAP IMPORTS SCRAP IMPORTS IN SCRAP SCRAP EXPORTS SCRAP EXPORTS SCRAP SCRAP EXPORTS IN SCRAP
GROSS WEIGHT COPPER CONT. GROSS WT. IMPORTS GROSS WT. COPPER CONT. EXPORTS GROSS WT. EXPORTS
1975 13,063 11,628 8,084 24,691 21,147 90,004 58,503 40,825 130,829 99,328
1976 14,241 17,956 12,413 32,197 26,654 76,706 45,232 33,995 110,701 79,227
1977 12,097 19,723 14,081 31,820 26,178 82,023 48,367 34,375 116,398 82,742
1978 15,436 19,018 13,199 34,454 28,635 106,717 69,366 49,076 155,793 118,442
1979 14,652 21,624 14,983 36,276 29,635 116,992 76,645 54,080 171,072 130,725
1980 16,053 19,162 13,704 35,215 29,757 129,767 84,349 61,225 190,992 145,574
1981 17,639 24,100 17,539 41,739 35,178 96,149 62,497 50,078 146,227 112,575
1982 16,459 25,449 18,844 41,908 35,303 91,592 59,535 54,419 146,011 113,954
1983 23,086 42,005 31,832 65,091 54,918 80,262 52,681 47,986 128,248 100,667
1984 23,005 42,369 32,016 65,374 55,021 108,833 70,415 80,810 189,643 151,225
1985 23,014 32,208 23,517 55,222 46,531 145,859 91,161 134,300 280,159 225,461
1986 27,216 39,017 28,844 66,233 56,060 152,971 98,867 136,422 289,393 235,289
1987 33,123 44,183 32,874 77,306 65,997 185,279 120,430 108,535 293,814 228,965
1988 37,152 50,028 36,122 87,180 73,274 200,682 129,969 119,773 320,455 249,742
1989 31,579 79,320 57,110 110,899 88,689 212,522 138,139 154,935 367,457 293,074
1990 35,904 96,710 71,071 132,614 106,975 184,766 120,098 139,624 324,390 259,722
1991 28,751 97,177 69,967 125,928 98,718 175,275 122,710 131,318 306,593 254,028
1992 52,398 116,352 83,773 168,750 136,171 145,441 104,708 101,195 246,636 205,903
1993 45,772 154,075 110,934 199,847 156,706 152,349 109,677 109,753 262,102 219,430
1994 102,000 58,400 42,000 160,400 144,000 217,567 156,822 142,292 359,859 299,114
1995 95,100 88,100 63,400 183,200 158,500 233,000 168,065 223,152 456,152 391,217
1996 90,300 121,824 87,700 212,124 178,000 195,324 126,750 197,416 392,740 324,166
1997 91,400 120,000 86,700 211,400 178,100 174,400 113,100 205,200 379,600 318,300
1998 54,400 111,000 80,100 165,400 134,500 193,400 139,248 114,100 307,500 253,348
1999 34,400 101,800 73,296 136,200 107,696 186,700 134,424 128,000 314,700 262,424
2000 30,900 112,800 81,216 143,700 112,116 257,800 185,616 227,700 485,500 413,316
2001 30,300 84,400 60,768 114,700 91,068 272,000 195,840 262,000 534,000 457,840
2002 29,253 70,857 51,017 100,110 80,270 297,762 214,389 213,203 510,965 427,592
2003 19,600 70,981 51,106 90,581 70,706 373,423 268,865 315,555 688,978 584,420
2004 23,400 78,300 56,376 101,700 79,776 388,689 279,856 325,000 713,689 604,856
2005 30,067 83,700 60,264 113,767 90,331 291,481 209,866 366,000 657,481 575,866
2006 24,927 92,598 66,671 117,525 91,598 404,091 290,946 399,029 803,120 689,975
e
2007 49,160 74,989 53,992 124,149 103,152 561,000 403,920 331,000 892,000 734,920

Sources: U.S. Dept. of Commerce, U.S. Bureau of Mines and U.S. Geological Survey.
e
Estimated on partial year data.

Table 8A. U.S. Domestic Exports of Copper and Copper Alloy Scrap1
(metric tons)
Type of Scrap 2004 2005 2006 2007
Jan-Nov
Refined Unspecified 325,118 0 0
No 1 0 106,802 67,319 44,189
No 2 and nonspecified 0 259,579 331,710 263,632
Total unalloyed scrap: 325,118 366,381 399,029 307,821
Red, SemiRed Brass >0.3%Pb 0 15,381 4,952 6,487
Brass > 0.3%Pb 82,871 0 0
Red Brass < 0.3%Pb 0 24,270 24,940 20,684
Yellow Brass > 0.3% Pb 0 37,586 57,054 68,551
Yellow Brass < 0.3% Pb 0 27,781 35,384 25,889
Brass < 0.3%Pb 71,743 0 0
Other copper scrap nesoi 234,075 0 0
Mixed copper & copper alloy 0 186,463 281,761 405,422
Total alloy & mixed scrap: 388,689 291,481 404,091 527,033

Grand Total Scrap Exports: 713,807 657,862 803,120 834,854

Data does not include reexports

e
Sources: USITC data webb, Dec. 2007, US Dept of Commerce.

75 Statistical Information
Table 9. U.S. Trade and Consumption of Copper Ash and Residues1 and Zinc Products
from Scrap. (thousand metric tons)

Product 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006

Exports:
Copper Ash & Residues (Gross Wt) 23.36 28.11 21.15 25.87 11.42 14.00 12.99 8.34 2.95 7.08 19.04 20.84 50.91
Zinc Dross, Skimmings, Residues (262019)
Zinc Content of Dross, etc. 18.21 17.77 14.02 11.33 8.70 4.56 14.15 16.59 25.38 17.69 13.22 8.77 4.22

Imports:
Copper Ash & Residues 2 1.06 1.74 1.68 0.49 1.20 0.66 0.76 0.63 0.70 2.34 8.18 4.22 6.41
Zinc Content of Product:
Zinc Dross & Skimmings (26201930) 13.91 13.29 15.99 18.66 23.83 22.66 17.59 13.69 17.30 15.79 18.50 17.76 33.07
Zinc Ash and Residues (26201960) 1.70 0.79 1.74 1.08 0.46 0.31 0.16 0.02 0.16 0.87 0.83 0.54 0.68
Total Zinc in Dross, etc. 15.60 14.08 17.73 19.74 24.30 22.97 17.75 13.71 17.46 16.66 19.33 18.31 33.75

Zinc Recovered from Scrap:

Zinc Recovered as Pb-free Zinc Oxide 36.80 33.60 47.10 47.90 64.20 35.90 23.10 19.70 15.60 14.90 15.00 15.00 15.0 e
Zinc Recovered from All Scrap 361.00 353.00 379.00 374.00 434.00 399.00 439.00 368.00 366.00 345.00 349.00 368.43 346.52
Zinc Recovered in Copper Alloys 3 172.68 169.63 179.63 193.97 201.00 206.70 223.00 205.00 198.00 176.00 168.00 176.00 159.00

Purchased Copper-base Scrap:

Lowgrade Copper Ash, Residues, etc.
Gross Weight Scrap 81.40 92.60 83.10 87.10 124.00 111.00 105.00 70.24 30.20 32.16 35.26 34.96 34.84
Copper Content 4 28.49 32.41 29.09 30.49 43.40 38.85 36.75 24.58 10.57 11.25 12.34 12.23 12.19

5
Low Grade Copper Base Shipments
Copper Content of Shipments 35.61 40.50 34.81 39.05 46.20 43.09 40.54 26.87 10.90 11.39 10.83 15.31 23.60
Gross Weight of Shipments 4 101.73 115.72 99.46 111.56 131.99 123.11 115.82 76.78 31.14 32.55 30.94 43.74 67.42

Data sources: USGS, USBM Minerals Yearbooks and Mineral Industry Surveys, Bureau of Census Trade Data.
NA = not available

1
Skimmings, drosses, ashes and residues containing 20-65% copper
2
Reported in copper content of material shipped.
3
Composition of secondary copper alloy production; 96% from scrap, 4% from other.
4
Assumption of 35% copper. USGS published series is gross weight.
5
Calculated shipments of low-grade ashes and residues from domestic producers.
(Consumption plus total exports minus imports of low grade ash and residues.)

Statistical Information 76
Table 10. Ingots, Foundry Castings, Brass- and Wire-Mill Semis and Copper Sulfate
Production in the United States (thousand metric tons)
Type of
Product 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006
Alloy Ingots:
Leaded & semi-red brass 92.0 88.6 97.9 97.3 103.0 87.1 88.6 64.7 68.4 68.7 69.4
Yellow Brass 6.8 7.4 6.2 6.0 5.7 6.0 4.7 4.4 5.9 5.9 5.6
Tin & High Leaded Tin Bronze 24.5 28.4 29.4 28.8 27.8 25.3 23.8 18.7 20.6 20.6 20.2
Nickel Silver 1.9 2.3 2.4 2.1 2.3 2.5 1.9 2.3 2.1 2.0 2.1
Aluminum & Manganese Bronze 15.3 15.0 15.9 13.9 13.9 16.6 13.8 12.9 14.3 14.2 14.0
Other Alloy Ingots 5.6 7.3 6.0 4.7 8.2 8.4 7.6 10.3 10.8 10.9 9.1
Hardeners and Master Alloys 13.7 13.4 12.9 13.2 13.8 11.3 5.4 5.4 5.5 5.8 7.6

Total Ingots 160.0 162.4 170.7 166.0 174.6 157.1 128.6 118.6 127.6 128.1 128.0

2
Foundry Castings 229.8 237.2 224.2 258.1 278.3 252.5 254.1 246.0 235.3 234.5 206.6

Copper Sulfate (Gross Weight) 43.6 48.4 44.0 52.7 55.5 55.2 49.2 32.1 25.1 25.6 19.5

Copper & Copper Alloy Powder1 10.7 10.6 7.7 7.6 7.7 7.6 7.6 6.9 0.1 0.4 0.2

Total Semifabricates 3,584.1 3,721.9 3,807.5 3,926.2 3,916.5 3,306.2 3,257.2 3,075.4 3,435.6 3,214.5 2,975.8
Copper Semis 2,768.5 2,846.5 2,933.4 3,028.1 3,012.5 2,634.9 2,532.6 2,404.4 2,708.1 2,520.3 2,273.8
Copper Alloy Semis 815.6 875.4 874.1 898.1 904.0 671.3 724.6 671.0 727.5 694.2 702.0

Data Sources: U.S. Geological Survey, U.S. Bureau of Mines, International Copper Study Group, Copper Development Assn.
1
Copper powder from scrap only. Some firms also used ingot to produce powder, amounts not shown here. U.S. Geol. Survey.
2
Consumption of raw materials at foundries. USGS Mineral Yearbook var. issues, Table 12.

Table 11. Standard Designations for Cast Copper Alloys

Percent (range) of principal metals in cast alloys

1
Alloy Class UNS Range Copper Tin Lead Zinc Aluminum Nickel Other
High copper alloys2 81300-82800 94.2-98.5 0.1 0.02 0.1 .10-.15 .10-3.0 .6-2.75
Red brasses & leaded
red brasses 83100-83800 82.0-94.0 .2-6.5 .10-7.0 1.0-9.5 0.005 .05-2.0 .005-.50
Semired brasses & leaded
semired brasses 84200-84800 75.0-82.0 2.0-6.0 2.0-9.0 7.0-17.0 .005-.01 .8-1.0 .02-.40
Yellow brasses & leaded
yellow brasses 84200-85800 57.0-75.0 .7-3.0 .8-5.0 20.0-41.0 .005-.8 .2-1.0 .005-.8
Manganese & leaded
manganese bronzes 86100-86800 53.5-68.0 .2-1.5 .2-1.5 22.0-42.0 .5-7.5 1.0-4.0 .4-5.0
Low & high silicon
bronzes & brasses 87200-87900 63.0-94.0 0.25 .15-1.0 .25-36.0 .15-.8 .20-.50 .01-5.5
Tin bronzes 90200-91700 79.0-94.0 6.0-20.0 .20-.50 .05-5.0 0.005 .10-2.0 .005-1.2
Leaded tin bronzes 92200-92900 78.0-90.0 5.5-17.0 .3-6.0 .25-5.0 0.005 .20-4.0 .005-.50
High leaded tin bronzes 93100-94500 68.5-86.0 1.5-14.0 2.0-34.0 .50-4.0 0.005 .25-1.0 .005-1.5
Nickel tin bronzes 94700-94900 79.0-90.0 4.0-6.0 .10-6.0 1.0-6.0 0.005 4.0-6.0 .005-.30
Aluminum bronzes 95200-95900 71.0-88.0 .1-1.0 .03-.10 .3-.5 6.0-13.5 .25-5.5 .05-14.0
Copper nickels 96200-96800 65.0-69.0 .005-.03 9.0-33.0 .05-1.8
Nickel- & leaded-nickel
silver & nickel bronze 97300-97800 53.0-67.0 1.5-5.5 1.0-11.0 1.0-25.0 0.005 11.0-27.0 .05-1.0
Leaded coppers 98200-98840 42.0-79.0 .25-5.0 21.0-58.0 0.1 .02-5.5
Special alloys3 99300-99750 54.0-61.0 .05-2.5 .02-2.0 .5-25.0 .25-11.5 .20-16.5 .02-45.0

Phosphor copper ASTM B52 86.0-90.0 10.0-14.0

Data Source: Copper Development Association Inc.

1
May include columbium.
2
Includes beryllium copper and chromium copper.
3
Special alloys include Incramet 8009, Incramute 1, while tombasil, etc.

77 Statistical Information
Table 12. Copper Recovered from Scrap in the United States and Form of Recovery
(metric tons, copper)

Form of Recovery 1999 2000 2001 2002 2003 2004 2005 2006

Electrolytic Refined 156,196 128,000 172,474 69,923 53,281 50,761 47,208 44,778
Fire-Refined 73,723 80,000 (w) (w) (w) (w) (w) (w)
Copper Powder 7,415 7,510 7,452 7,439 8 48 314 134
Copper Castings 647 839 323 300 338 574 547 612
Total unalloyed 237,981 217,000 180,249 77,662 53,627 51,383 48,069 45,524

In Brass and Bronze 1,000,462 1,010,000 893,363 876,216 818,087 839,975 836,591 892,380

In Alloy Iron and Steel 599 549 506 425 974 1,017 985 786
In Aluminum Alloys 78,200 74,900 64,006 63,177 59,258 60,446 54,517 67,964
In Other Alloys 125 125 117 122 27 28 32 36
1
In Chemical Compounds 11,775 11,700 11,248 12,022 12,255 12,255 12,255 8,214

Total 1,329,142 1,314,274 1,149,489 1,029,624 944,228 965,094 952,502 968,500

Source: USGS Minerals Yearbook, Copper Chapter

1
1999-2006 reflect addition of copper sulfate and other copper chemical producers, not included in previous data.
(w) Fire Refined included in electrolytic refined total. Data withheld.

Statistical Information 78
Table 13. List of U.S. Primary Brass and Tube Mills

COMPANY NAME CITY STATE

1. Ampco Metal Inc. Chicago Illinois
2. Ampco Metal Inc. Milwaukee Wisconsin
3. Anchor Bronze & Metals Bay Village Ohio
4. Ansonia Copper & Brass Ansonia Connecticut
5. Ansonia Copper & Brass Inc. Waterbury Connecticut
6. Brush Wellman Inc. Elmore Ohio
7. Brush Wellman Inc. Reading Pennsylvania
8. Cambridge Lee Industries Reading Pennsylvania
9. Cerro Flow Products.(Copper tube) Sauget Illinois
10. Cerro Flow Products (Copper Tube) Shelbina Missouri
11. Cerro Flow Products (Heatcraft)(Copper Tube) Bossier City Louisiana
12. Cerro Metal Products Bellefonte Pennsylvania
13. Cerro Metal Products (closed 2002) Paramount California
14. Chase Copper & Brass Montpelier Ohio
15. Chicago Extruded Metals Cicero Illinois
16. Concast Metal Products Mars Pennsylvania
17. Concast Metal Products Birmingham Ohio
18. Copperweld Bimetallics Division of Copperweld Fayetteville Tennessee
19. Drawn Metal Tube Co. Tomaston Connecticut
20. The Electric Materials Co. Northeast Pennsylvania
21. Extruded Metals Belding Michigan
22. Halstead Industries (Mueller Industries) Greensboro North Carolina
23. Heyco Metals Reading Pennsylvania
24. Howell Metal Company New Market Virginia
25. Hussey Copper Ltd. Leetsdale Pennsylvania
26. Hussey Copper Ltd. Eminence Kentucky
27. Kobe Copper Products Pine Hall North Carolina
28. MAC Metals Inc. Kearny New Jersey
29. The Miller Co. Meriden Connecticut
30. Mueller Brass Port Huron Michigan
31. Mueller Copper Tube Co. Fulton Mississippi
32. Mueller Copper Tube Products Co. Wynne Arkansas
33. National Bronze & Metals (Ohio), Inc Lorain Ohio
34. National Copper Products Dowagiac Michigan
35. NGK Metals Corp. Reading Pennsylvania
36. NGK Metals Corp Sweetwater Tennessee
37. NIBCO Inc. Stuarts Draft Virginia
38. Nippert Co. (Outokumpu) Delaware Ohio
39 Olin Corp. E. Alton Illinois
Olin Corp (closed 2003) Indianapolis Indiana
40. Outokumpu American Brass Inc Buffalo New York
41. Outokumpu Copper Franklin, Inc. Franklin Kentucky
42. Phelps Dodge Specialty Copper Elizabeth New Jersey
43. PMX Industries Inc. Cedar Rapids Iowa
44. Revere Copper Products Rome New York
45. Revere Copper Products New Bedford Massachusetts
46. Scott Brass Inc. Cranston Rhode Island
47. Scott Brass, Inc. Mishawaka Indiana
48. Ullrich Copper Inc. (Div. Of Hussey Copper) Kenilworth New Jersey
49. Valleycast Inc. (Outokumpu) Appleton Wisconsin
50. Waterbury Rolling Mills Waterbury Connecticut
51. Wolverine Tube Inc. (Hdqs Huntsville, Ala) Decatur Alabama
52. Wolverine Tube Inc. Shawnee Oklahoma
53. Wolverine Tube Inc.(Closed Nov. 2006) Jackson Tennessee
54. Wolverine Tube Inc.(closed 2003) Boonville Mississippi

79 Statistical Information
 Table 14. List of U.S. Ingot makers, Secondary Smelters and Refiners, and Secondary
Hydrometallurgical Plants

Company Name City State Remarks Status

Admetco Inc. Fort Wayne Indiana Phos copper, copper anodes Operating
American Nickel Alloy Mfg. Corp New York New York Operating
Atlas Pacific Altadena California Was Fed. Weiner Metals, 1992 Operating
Belmont Smltg & Refg. Works, Inc Brooklyn New York Operating
Brush Wellman Inc. Cleveland Ohio Beryllium Master Alloy Operating
California Metal - X Los Angeles California Operating
Colonial Metals Co. Columbia Pennyslvania Operating
Federal Metal Co. Bedford Ohio Operating
H. Kramer & Co. Chicago Illinois Operating
Handy & Harman Attleboro Maine Operating
I Schumann & Co. Bedford Ohio OGDEN Alloys Inc. Operating
Kearny Smelting & Refining Corp. Kearny New Jersey Operating
Lee Brass (Amcast Industrial) Anniston Alabama Foundry & ingotmaker Operating
Metallurgical Products Co. West Chester Pennsylvania Master alloys, Plating Anode Operating
Milward Alloys, Inc. Lockport New York Operating
Monett Metals Inc. Chicago Illinois New name, 5/92 Operating
National Bronze & Metals Houston Texas Founded 1983, Ohio foundry Operating
National Metals Inc. Leeds Alabama Operating
P D Wire & Cable Elizabeth New Jersey Specialty Copper, Copper Alloy Operating
R. Lavin & Sons, Inc. North Chicago Illinois N. Chicago Ref. & Smelters Closed 2003
River Smelting & Refining Co. Cleveland Ohio Closed 2004
SIPI Metals Corp. Chicago Illinois Operating
South Bend Sm & Rfg Co. South Bend Indiana Operating
Specialloy Inc Chicago Illinois Operating
Univertical Corporation Angola Indiana Phos copper, copper anodes Operating
The G.A. Avril Co. Cincinnati Ohio Avril G.A. Brass & Bronze Operating
W.J. Bullock Fairfield Alabama Operating

Secondary Smelters and Refiners:

American Iron and Metal Warrenton Missouri Fire Refinery, ingot, wirebar Operating
Amrod Corp Newark New Jersey Wirerod casting, cathode Operating
Cambridge-Lee Industries Reading Pennsylvania Fire Refinery, billet casting Operating
Cerro Copper Products E. St Louis Illinois Fire Refinery, billet casting Operating
Cerro Copper Casting Co. Mexico Missouri Billet casting, cathode Operating
Cerro Copper Products E. St Louis Illinois Electrolytic refinery/smelter Closed, 1998
Chemetco (Concorde Metals) Alton Illinois Secondary smelter, anode Closed, 2001
Essex Wire (Superior Essex) Ft Wayne Indiana Fire Refinery, wire rod Operating
Franklin Smelting & Refining Co. Philadelphia Pennsylvania Secondary smelter Closed, 1996
Gaston Copper Co. (Nassau) Gaston South Carolina Secondary smelter, refinery Closed, 1994
Southwire Carrolton Georgia Secondary smelter, fire refinery Closed, 2000
Textin Corp. Texas City Texas Fire Refinery Closed, 1990

Secondary Chemical and Hydrometallurgical Recovery Plants

American Chemet Helena Montana Copper Chemicals Operating
Encyle Texas (Div. Of Asarco) Corpus Christi Texas Processes cu-bearing waste Operating
Griffin Corp.(Kocide Chemical) Several Plants GA, AZ, TX Copper Chemicals Operating
Heritage Environmental Services Indianapolis Indiana Processes cu-bearing waste Operating
Hydromet Environmental Inc. Newman Illinois Processes cu-bearing waste Operating
MacDermid Waterbury Connecticut Copper Chemicals Operating
Old Bridge Chemicals Inc Old Bridge New Jersey Copper Chemicals Operating
Peninsula Copper Inc. Hubbell Michigan Copper Chemicals Operating
Phibro-Tech(4 US, 1 French Plant) Santa Fe Springs California Copper Chemicals Operating
(Philip Bros. Chemical) Joliet Illinois Copper Chemicals Operating
Garland Texas Copper Chemicals Operating
(CP Chemicals) Sumter South Carolina Copper Chemicals Operating
SCM Metals (Hoganas AB) Cleveland Ohio Copper Powder Operating
U.S. Filter Recovery Service Minneapolis Minnesota Processes cu-bearing waste Operating

Statistical Information 80
Table 15. Copper and Copper Alloy Scrap Types, Showing General Range in Compositions
(in percent metal content)

Copper Tin Lead Zinc Aluminum Nickel/Cobalt Manganese Other

Scrap Type Low High Low High Low High Low High Low High Low High Low High Low High

Unalloyed Copper Scrap

No. 1 Copper 99.00 99.90
No. 2 Copper, mixed, light 94.50 99.00
Other 94.00 99.00

Copper-base Alloy Scrap

Red Brass 87.00 98.00 0.20 0.35 0.10 3.00 2.00 12.00 0.00 0.01 0.05 1.00 0.03 0.08
Leaded red & semired brass 75.00 86.00 2.00 6.00 3.50 7.00 4.00 17.00 0.01 0.30 2.00 0.10 0.40
Yellow, leaded and
heavy brass 57.00 75.00 0.70 2.00 0.20 5.00 20.00 41.00 0.01 8.00 0.20 1.00 0.20 0.50 0.01 0.80
Yellow & low brass, and
other copper-zinc brasses 65.00 82.43 0.02 0.30 17.50 31.50 0.05 0.10
Copper/nickel/zinc alloys 42.00 73.50 1.50 5.50 0.03 11.00 1.00 25.00 0.00 0.01 4.00 27.00 0.50 2.50 0.15 1.50
Copper/nickel alloys 62.27 97.90 0.01 0.03 0.00 1.00 2.00 33.00 0.05 2.50 0.05 1.20
High leaded tin bronzes 45.50 91.50 1.50 14.00 7.00 34.00 0.00 4.00 0.00 0.01 0.00 1.00 0.00 1.50
Tin brasses 57.00 88.00 0.25 4.00 0.05 2.50 3.75 42.70 0.00 0.10 0.00 0.50 0.00 0.15 0.00 1.00
Tin bronze/phosphor bronze 71.19 93.00 6.00 20.00 0.25 0.50 0.25 5.00 0.01 0.01 0.50 2.00 0.00 0.10 0.00 1.20
1
High coppers 93.88 99.98 0.00 0.10 0.00 0.02 0.00 0.10 0.00 0.15 0.00 3.00 0.02 2.75
Manganese bronze 35.60 68.00 0.50 1.50 0.20 0.40 22.00 42.00 0.50 7.50 0.00 4.00 0.10 5.00 0.40 4.00
2
Aluminum bronze 71.00 88.00 0.00 0.05 6.00 13.50 0.00 5.50 0.00 14.00 0.05 5.00
Silicon bronze & brass 63.00 94.00 0.00 0.25 0.15 1.00 0.25 36.00 0.00 0.80 0.00 0.20 0.00 1.50 0.00 0.20

Common Scrap Groups

Water meters 62.00 65.00 0.80 1.50 33.00 36.40 0.00 0.15 0.15
Auto radiators (Ocean) 68.00 70.00 3.00 5.00 7.00 12.00 10.00 15.00
3
Cocks & faucets (Grape) 65.00 77.00 0.00 2.00 2.00 6.00 15.00 33.00 x x
Cartridge cases and brass 68.50 71.50 0.07 0.07 28.40 31.40
4
Refinery brass (drink) 61.30 39.00
Aluminum/copper radiators 45.60 0.02 54.00 0.50 0.20
Copper-bearing material 20.00 60.00 40.00 80.00

Sources: Copper Development Association Inc. and ISRI, 1989, U.S. Bureau of Mines.
1
Be, Cd, Cr coppers
2
Al, Fe, Ni alloys
3
Mixed red and yellow brass plumbing fixtures, including nickel/chrome-plated. Free of zinc die-cast and aluminum parts.
4
Limit 5% iron, includes copper, brass and bronze alloyed metal.

81 Statistical Information
Table 16. Principal U.S. Scrap Source Materials for Copper
(thousand metric tons, copper)

Copper from 1950 1960 1970 1980 1990 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006
Type of Scrap

New Scrap:
Copper-base 440 396 664 804 751 923 913.8 902.7 906 795 802.9 700.9 735.1 729.6 780.4
Aluminum-base 6 5 10 20 23 44 42.4 46.2 45.5 38.6 37.14 36.45 38.76 39.62 46.98
Nickel-base 0.2 0.1 0.1 0.2 0.04 0.09 0.103 0.094 0.018 0.018 0.018 0.018 0.018 0.018 0.018
Zinc & tin-base <.01 0.03 0.01 0.02 nil nil nil nil nil nil nil nil nil nil nil
Total 446 401 674 824 774 967 956.3 950.5 952 833 840.1 737.4 773.9 769.3 827.4

Old Scrap:
Copper Base 437 387 453 596 502 466 431.8 349.5 334 292 165.4 184.9 168.8 168 119.6
Aluminum-base 2 2 4 15 34 30 34 31.2 28.4 23.96 23.98 21.74 22.12 15.03 21.31
Nickel-base 1.00 0.50 0.70 0.10 0.08 0.03 0.05 0.04 0.17 0.173 0.148 0.213 0.279 0.214 0.19
Zinc- & tin-base 0.09 0.08 0.04 0.1 0.03 0.02 0.04 0.03 0.032 0.029 0.029 0.027 0.029 0.033 0.038
Total 440 390 458 611 536 497 465.9 380.9 363 316.5 189.5 206.8 191.2 183.2 141.1

Total Copper in Scrap 886 791 1,132 1,435 1,310 1,464 1,422 1,331 1,310 1,150 1,030 944 965 953 969

Source: U.S. Bureau of Mines and U.S. Geological Survey, Minerals Yearbooks, var. issues.

Statistical Information 82
Table 17A. U.S. Copper Scrap and Copper Alloy Consumption, 1973–19891
(metric tons)

Scrap Consumption by: 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989
Plant type:
Brass Mill 704,623 644,908 470,252 600,968 615,205 637,942 703,138 608,205 633,879 508,478 624,466 675,472 621,023 627,628 683,431 757,047 725,586
Secondary Smelters & Refiners 912,585 895,536 611,539 709,941 745,980 918,238 1,281,257 1,168,398 1,115,275 946,480 693,678 689,375 736,034 804,344 823,032 797,682 828,905
Foundries and misc. plants 72,994 72,104 54,520 62,516 67,238 86,799 88,831 74,302 76,413 59,889 63,472 68,610 54,722 63,037 72,173 64,507 66,097
Total, gross weight: 1,690,202 1,612,548 1,136,311 1,373,425 1,428,423 1,642,979 2,073,226 1,850,905 1,825,567 1,514,847 1,381,616 1,433,457 1,411,779 1,495,009 1,578,636 1,619,236 1,620,588
Source: 1
Old Scrap 625,009 620,300 441,156 518,504 555,140 664,289 830,335 791,080 776,984 659,574 574,376 572,311 570,923 612,896 675,088 644,314 673,258
New Scrap 1,065,194 992,248 695,155 854,921 873,283 978,690 1,242,891 1,059,825 1,048,583 855,273 807,240 861,146 840,856 882,113 903,548 974,916 943,501
Ratio Old/New 0.59 0.63 0.63 0.61 0.64 0.68 0.67 0.75 0.74 0.77 0.71 0.66 0.68 0.69 0.75 0.66 0.71
Type of Scrap:
Unalloyed copper:
No. 1 scrap 382,442 373,164 259,407 302,214 304,928 331,910 392,112 380,386 346,295 279,877 271,990 270,228 348,087 389,198 410,636 416,655 418,893
No. 2 scrap, mixed 314,218 311,240 220,005 244,891 262,413 326,112 447,267 466,951 466,174 417,004 324,665 367,436 278,047 338,031 383,862 409,332 392,755
Total Unalloyed: 696,660 684,404 479,412 547,105 567,341 658,022 839,379 847,337 812,469 696,881 596,655 637,664 626,134 727,229 794,498 825,987 811,648
Red Brass 2 76,831 74,204 48,959 62,868 73,452 84,052 89,427 75,799 77,170 61,264 57,277 64,496 56,196 54,592 61,222 53,638 68,448
Cartridge brass 80,788 70,261 50,859 70,963 74,601 82,852 80,520 61,354 67,948 54,057 66,534 70,781 67,221 71,549 78,461 139,074 126,224
Yellow and low Brass 3 394,438 353,487 259,533 338,956 359,569 385,836 408,392 355,194 355,772 288,327 345,638 387,165 347,074 314,405 341,347 338,949 326,167
Automobile Radiators 62,364 62,791 48,372 61,762 73,051 83,453 94,123 65,546 65,058 58,942 64,814 75,440 77,230 55,555 62,260 104,364 96,395
Bronze 31,366 29,173 21,876 22,441 24,413 23,299 24,574 22,461 21,708 18,195 20,949 24,593 19,994 20,030 21,050 21,296 21,092
Nickel silver/cupronickel 29,842 36,415 38,127 33,528 28,247 18,894 28,449 17,265 22,756 17,564 22,912 21,811 15,819 13,229 9,617 14,968 23,619
Aluminum bronze 1,781 1,358 909 1,244 1,043 941 1,605 1,551 1,705 1,396 1,136 972 969 970 965 1,005 2,696
Low-grade scrap and residue 4 307,581 291,290 183,123 230,722 223,403 303,337 500,872 400,271 397,935 315,294 202,094 140,318 111,243 115,937 95,266 101,223 102,448
Refinery brass and other scrap 8,551 9,165 5,141 3,837 3,302 2,293 5,885 4,127 3,046 2,927 3,607 10,217 89,899 125,555 113,950 18,732 41,806
Total Alloyed Scrap 993,542 928,144 656,899 826,320 861,082 984,957 1,233,847 1,003,568 1,013,098 817,966 784,961 795,793 785,645 767,780 784,138 793,249 808,940
Copper recovered from scrap:
Refined from scrap 421,953 450,787 312,513 340,335 349,646 420,103 498,459 515,083 482,837 467,549 401,668 306,537 371,787 406,000 415,000 446,000 480,000
Unalloyed powder & castings 17,690 14,878 10,002 14,128 15,075 17,017 17,812 19,473 20,966 14,016 17,186 31,652 15,882 8,446 8,757 10,478 9,282
Total unalloyed products 439,643 465,665 322,515 354,463 364,721 437,120 516,271 534,556 503,803 481,565 418,854 338,189 387,669 414,446 423,757 456,478 489,282
Brass and bronze 710,688 714,062 518,902 635,795 670,712 755,978 976,402 850,188 850,546 660,152 625,349 735,154 716,833 662,242 736,725 800,221 774,770
In aluminum alloys 34,093 34,739 35,909 42,653 44,218 48,153 53,608 47,306 47,728 41,930 36,704 43,511 29,423 45,171 47,932 45,632 41,719
From other alloys & chemicals 6,080 5,081 4,426 6,064 5,774 5,984 6,244 5,377 5,320 3,819 2,672 3,060 5,159 4,669 4,672 3,797 2,684

Total copper from scrap: 1,190,503 1,219,547 881,752 1,038,975 1,085,425 1,247,235 1,552,525 1,437,427 1,407,397 1,187,466 1,083,579 1,119,914 1,139,084 1,126,528 1,214,059 1,306,891 1,308,455

Source: U.S.G.S. and U.S.B.M. Minerals Yearbooks and Mineral Industry Surveys.
W= Withheld, data in other scrap.
1
Gross Weight.
2
Includes Railroad car boxes.
3
Includes leaded-yellow brass.
4
Includes low-grade scrap and residues at primary and secondary smelters and refiners.
5
1999-2007 Includes copper sulfate and other chemicals.

83 Statistical Information
 Table 17B. U.S. Copper Scrap and Copper Alloy Consumption, 1989–20071
(metric tons)

Scrap Consumption by: 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007e
Plant type:
Brass Mill 754,386 695,200 854,771 744,000 862,000 886,000 909,000 1,010,000 1,020,000 1,046,800 1,070,000 918,508 929,616 840,921 880,291 874,019 895,437 810,000
Secondary Smelters & Refiners 777,833 802,139 748,953 892,000 779,000 695,000 655,000 693,000 644,000 501,000 421,000 370,051 211,283 187,082 182,893 192,465 179,247 181,560
Foundries and misc. plants 75,654 55,680 64,800 60,700 67,000 71,500 61,300 62,700 58,700 79,900 96,200 87,478 86,959 85,888 80,742 81,671 75,461 76,000
Total, gross weight: 1,607,873 1,553,019 1,668,524 1,696,700 1,708,000 1,652,500 1,625,300 1,765,700 1,722,700 1,627,700 1,587,200 1,376,037 1,227,858 1,113,891 1,143,926 1,148,155 1,150,145 1,067,560
Source: 1
Old Scrap 696,125 696,125 731,596 741,817 669,000 621,000 583,000 594,000 574,000 464,000 414,000 257,875 200,290 224,742 202,441 201,286 146,606 147,000
New Scrap 856,892 856,892 936,928 954,883 1,040,000 1,030,000 1,040,000 1,170,000 1,150,000 1,164,000 1,170,000 1,119,121 1,027,566 889,149 941,485 946,869 1,003,519 920,560
Ratio old/new 0.81 0.81 0.78 0.78 0.64 0.60 0.56 0.51 0.50 0.40 0.35 0.23 0.19 0.25 0.22 0.21 0.15 0.16
Type of Scrap:
Unalloyed copper:
No. 1 scrap 424,128 430,790 448,285 480,600 513,900 572,000 533,500 597,800 583,900 538,000 566,900 512,117 484,839 478,724 480,020 478,890 486,114 421,480
No. 2 scrap, mixed 342,658 335,456 380,284 385,690 361,350 262,090 254,480 271,670 240,500 154,000 132,120 111,416 51,694 38,032 38,602 45,370 45,890 46,700
Total Unalloyed: 766,786 766,246 828,569 866,290 875,250 834,090 787,980 869,470 824,400 692,000 699,020 623,533 536,533 516,756 518,622 524,260 532,004 468,180
Red Brass 2 74,954 62,126 70,151 61,400 62,340 81,910 81,090 79,650 71,700 62,800 73,430 67,359 53,185 47,782 50,331 45,159 40,107 40,000
Cartridge brass 97,726 56,068 51,619 54,300 61,100 49,900 46,100 66,800 82,600 78,400 72,600 36,430 70,881 80,538 86,659 94,639 94,084 90,000
Yellow and low Brass 3 371,656 351,351 393,268 409,560 454,850 424,220 459,930 488,630 486,200 497,200 518,980 464,569 441,930 356,916 366,239 366,308 362,542 349,800
Automobile Radiators 94,947 88,621 77,129 71,800 70,970 79,910 70,400 79,870 61,610 55,200 49,450 48,223 36,202 30,409 29,276 29,345 31,139 31,000
Bronze 18,608 20,683 25,001 23,600 23,200 25,000 25,900 27,400 27,500 23,670 22,700 31,841 32,481 25,630 29,504 28,208 29,533 29,000
Nickel silver/cupronickel 21,303 17,952 14,708 14,800 21,900 20,500 23,300 17,800 17,400 22,300 28,100 19,281 15,430 17,371 20,906 18,683 19,114 18,000
Aluminum bronze 2,246 w w w w w w w w w w w w w w w w w
4
Low-grade scrap and residue 136,395 141,250 161,785 161,000 81,400 92,600 83,100 87,100 124,000 111,000 105,000 70,240 30,196 32,157 35,261 34,955 34,839 35,000
Refinery brass and other scrap 31,102 48,721 46,516 33,710 57,180 45,840 48,180 45,070 27,000 19,060 18,910 15,367 11,019 6,331 7,127 6,581 6,763 6,580
Total Alloyed Scrap 841,087 786,773 839,955 830,410 832,750 818,410 837,320 896,230 898,010 841,000 889,170 753,310 691,324 597,134 625,303 623,878 618,121 599,380
Copper recovered from scrap:
Refined from scrap 440,757 417,757 433,223 459,788 391,000 352,000 345,000 396,000 349,000 229,919 208,000 172,474 69,923 53,281 50,761 47,207 44,778 45,760
Unalloyed powder & castings 9,143 8,330 9,316 9,182 11,297 11,299 10,806 10,619 8,305 8,062 8,349 7,775 7,439 346 622 861 746 800
Total unalloyed products 449,901 426,087 442,539 469,601 403,000 364,000 355,000 407,000 357,000 237,981 216,349 180,249 77,362 53,627 51,383 48,068 45,524 46,560
Brass and bronze 800,772 727,618 776,295 753,968 861,000 887,000 892,000 981,000 987,432 1,000,462 1,010,000 893,363 876,216 818,087 839,975 836,646 845,976 850,000
In aluminum alloys 56,489 44,277 55,607 61,049 62,800 64,600 70,700 75,000 76,600 78,200 73,900 64,006 63,177 59,258 60,436 54,517 67,964 60,000
5
From other alloys & chemicals 3,412 2,708 1,986 1,077 334 307 415 365 215 11,925 14,023 11,871 12,144 13,256 13,300 13,272 9,036 10,000

Total copper from scrap: 1,309,529 1,200,690 1,276,426 1,285,695 1,330,000 1,320,000 1,320,000 1,460,000 1,422,000 1,328,568 1,314,272 1,149,490 1,029,623 944,228 965,094 952,503 968,500 966,560

Source: U.S.G.S. and U.S.B.M. Minerals Yearbooks and Mineral Industry Surveys.
W= Withheld, data in other scrap.
1
Gross Weight.
2
Includes Railroad car boxes.
3
Includes leaded-yellow brass.
4
Includes low-grade scrap and residues at primary and secondary smelters and refiners.
5
From 1999 forward, includes copper sulfate and other chemicals.

Statistical Information 84
Table 18. Estimated Secondary By-products for 1998, by Plant-Type Sector
(metric tons)

Other Residues Slag Furnace Total All

Plant type Zinc Oxide Grindings Drosses Dusts, Fines, Total: Other and Linings and By-Products
Sludges etc. Residues2 Skimmings3 Bricks

Brass, Tube &

Wire Rod Mills1 4,440 1,375 3,472 9,079 13,926 28,476 9,700 56,542

Foundries 428 2,327 425 6,978 9,730 25,453 3,137 38,748

Ingotmakers1 9,479 203 50 1,199 1,452 39,142 1,678 51,751

Grand Totals 14,347 3,905 3,947 17,256 25,108 93,071 14,515 147,041

Data derived from 1994 and 1998 Copper Development Association surveys. The combined data represents responses by more than 70%
of the copper and brass mill and ingot-maker production. The response rate for foundries was somewhat lower. All data was rationalized to
represent each entire 1998 industry sector, using comparative production data from the U.S. Geological Survey.

1
Includes fire refineries and cupolas at these facilities.
2
Other residues includes grindings, Ni and Cu drosses, dusts, fines, waste water sludges, pickle liquor products, turnings and other products.

3
It is estimated that about 28% of slag and skimmings are reprocessed in-house.

85 Statistical Information
Table 19. Particulate Emission Factors for Furnaces Used in Secondary Copper Smelting
and Alloying Process1
(units in kilograms of materials processed)

Type of Emission Emission Emission

Furnace Emissions Total Factor Factor Factor
and Charge Type Control Particulate Rating PM-102 Rating Lead Rating

Cupola
Insulated Copper Wire ESP 5 B ND E ND NA
Insulated Copper Wire None 120 B 105.6 E ND NA
Scrap Copper and Brass ESP 1.2 B ND NA ND NA
Scrap Copper and Brass None 35 B 32.1 E ND NA

Reverberatory furnace
Copper Baghouse 0.2 B ND NA ND NA
Red/yellow Brass None ND NA ND NA 6.6 B
Other Alloy (7%) None ND NA ND NA 2.5 B
High Lead Alloy (58%) None ND NA ND NA 25 B
Brass and Bronze Baghouse 1.3 B ND NA ND NA

Rotary furnace
Brass and Bronze ESP 7 B ND NA ND NA
Brass and Bronze None 150 B 88.3 E ND NA

Crucible, pot furnace

Brass and Bronze ESP 0.5 B ND NA ND NA
Brass and Bronze None 11 B 6.2 E ND NA

Electric arc furnace

Copper Baghouse 0.5 B ND NA ND NA
Brass and Bronze Baghouse 3 B ND NA ND NA

Electric induction furnace

Copper Baghouse 0.25 B ND NA ND NA
Brass and Bronze Baghouse 0.35 B ND NA ND NA

Fugitive emissions2
Cupola None ND NA 1.1 E ND NA
Reverberatory None ND NA 1.5 E ND NA
Rotary None ND NA 1.3 E ND NA
Crucible None ND NA 0.14 E ND NA
Electric induction None ND NA 0.04 E ND NA

ESP = Electrostatic Precipitator. NA= Not Available. ND = Not Detected.

1
Sources unpublished data, U.S. EPA. URL: http://www.epa.gov:80/ttnchie1/ap42pdf/c12s09.pdf
EPA document 450/4-90-003
2
PM-10 and fugitive emissions listed in Air Facility Subsystem Source Classification Codes and Emission
Factor Listing for Criteria Air Pollutants, U.S. EPA 450/4-90-003, March 1990.

Statistical Information 86
APPENDIX A on the Commodity Exchange was suspended July 23,
1941, through July 15, 1947. Some restrictions on
transactions in copper and brass scrap, which had
remained in effect after the wartime price ceilings
were lifted on November 10, 1946, were removed at
Historical Review of U.S. Export Controls the end of the first quarter of 1947, including a
on Copper-base Scrap: regulation that provided for allocation of cartridge
brass from military sources. There were substantial
Copper and copper-base scrap becomes particularly increases in the prices of nonferrous metals following
valuable during periods of military conflict and the removal of price ceilings.
economic expansion. The following summary of
events prompting export and other controls on copper Under the Defense Production Act of 1950, defense
and copper scrap during the 1941-1970 period is measures included ceiling prices for all copper and
extracted from the copper chapters of the U.S. Bureau copper alloy materials as well as strict export controls.
of Mines Minerals Yearbooks. On Sept. 12, 1950, the National Production Authority
(NPA) was organized, and it immediately issued its
Supplies of copper in the United States were first regulation, which limited inventories of all
inadequate to fill requirements over much of the materials, including scrap, to a reasonable working
period between the end of World War II and 1970. quantity. Despite all efforts to increase supplies, the
Refer to Figure 15 for a review of major historical copper available during 1951 fell below that of 1950. A
events related to the industrial consumption of copper labor strike at midyear compounded the shortage.
in the United States. Because of the periodic shortage Some 55,000 tons of copper were released from the
of copper supplies, all copper raw materials, including National Stockpile.
scrap, were subject to export controls. This was
particularly true during the period of the Korean The world shortage of copper in 1951 led to placing
Conflict (1949-1953) and the Vietnam War (1964- copper under international allocation among the
1973). During the World War II period, controls were Market Economy Countries. The controls that had
exercised on all copper materials under authority of been inaugurated under the Defense Production Act
the War Production Board, the National Defense of 1950 were extended. On July 13, 1951, the
Advisory Commission and the Office of Production National Production Authority (NPA), which
Management to insure the most efficient use and reinstituted the Controlled Materials Plan (used
allocation. effectively in World War II for copper), announced that
copper raw materials would be placed under complete
When it became evident during the World War II allocation control, effective August 1. Quotas were
period that copper was rapidly becoming scarce, the established by the International Materials Conference
first measures for increasing imports were passed and for the 4th quarter of 1951. The member countries
mandatory priorities were issued. Among the first voluntarily accepted restrictions upon quantities to be
steps taken to conserve and increase copper supply consumed. While price controls were in effect in the
was the placement of copper on the list of materials United States, international copper prices soared and
requiring license for export. Since such a large were higher than any year since 1918.
proportion of raw materials was comprised of scrap,
this portion of supply was controlled by a number of Trading in copper on the Commodity Exchange of
orders including Supplementary Order M-9-b of New York was temporarily suspended between
September 30, 1941, which was issued to assure that January 29, 1951, and June 1, 1953. Orders issued
scrap generated would be returned to mills. According by NPA in 1950 that affected copper were: Regulation
to orders issued Dec. 31, 1941, copper-base scrap 1, which prohibited accumulation of excessive
could be purchased by consumers only. Unalloyed inventories by limiting the quantities of materials that
copper scrap was allocated to replace refined copper could be ordered, received or delivered; Order M-12,
wherever possible, and fabricator segregation of brass which reduced civilian use of copper by 15% in
scrap was made mandatory so that the scrap could be January and February, and 20% in March 1951; Order
remelted at brass mills for reuse in wrought products. M-11, which set rules for placing, accepting and
Although refining of copper from yellow-brass scrap scheduling rated orders for copper and copper-base
was subsidized to some extent by the government, alloys; and Order M-16, which aimed at maintaining
beginning in April 1942, by amendments to the scrap the flow of copper and copper-base alloy scrap
price schedule, total production of secondary refined through normal channels and limited toll agreements,
copper was less than in 1941. except as authorized.

Many of the supply and price restrictions remained in Copper supply continued to be inadequate in 1952,
place throughout the WWII period. Trading of copper with less copper available in 1952 than in 1951. A

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 Figure 15. U.S. Industrial Copper Consumption Trends
and Response to Major Historical Events, 1924-2007
1,000 metric tons, refined copper
3,500

US Industrial Recovery 1988-1999

3,000

2,500
Vietnam War-1964-1973

2,000 World War II Loss of U.S.

1941-1948 Manufacturing
Capacity-
1,500 9 mo. mine 1982 1999-2007
srrike-1967-68
Recession
Depression 1974
1,000 6 mo. mine Oil Crisis
strike- 1959

500

0
19
19
19
19
19
19
19
19
19
19
19
19
19
19
19
19
19
19
19
19
19
19
19
19
19
19
20
20
24
27
30
33
36
39
42
45
48
51
54
57
60
63
66
69
72
75
78
81
84
87
90
93
96
99
02
05
Years

Sources: U.S. Bureau of Mines, U.S. Geological Survey, Statistical Publications

further release of 22,000 tons of copper was In 1956, new production highs were established. The
authorized from the National Stockpile, to meet the record output resulted from high prices and mine
temporary emergency. Following the Office of Price production that was uninterrupted by labor strikes for
Stabilization permission to raise prices for foreign the first time since 1952. By the end of the year, the
copper and to pass on to consumers most of the supply situation changed to one in which copper was
costs, the situation improved, so that copper was in surplus of requirements. In 1956, most of the
nearly in balance by year-end. Probably the most copper exported from the United States was refined or
outstanding feature of the year, and the most as advanced manufacture forms. Refined and
controversial, was the multiple prices for copper unrefined copper of foreign origin, except that
(foreign vs. domestic) as domestic prices were produced from Canadian-origin copper scrap,
controlled by the General Ceiling Price Regulation that continued under open-end licensing. Refined copper
had been in force since January 1951. The price for of domestic origin and that produced from Canadian-
copper in foreign markets in late 1952 was lower than origin scrap generally was not approved for export. As
it was in the USA, in contrast with the earlier situation the copper supply situation eased during the year, the
in which foreign prices sharply exceeded those in the export quotas were changed. On June 22, 1956, the
United States. Exports of copper continued to be Bureau of Foreign Commerce (BFC) announced
subject to export control in 1952; exports of refined increases in the quotas for new and old copper-base
copper rose 31%, nonetheless. scrap containing 40% or more copper, copper-base
alloy ingots and other crude forms.
Early in 1953, the situation had eased to the point
where price controls and national and international Copper production declined in early 1958, owing
allocations of copper were abandoned, although largely to voluntary restrictions in output following the
military and Atomic Energy Commission needs were surpluses of 1957. Effective Nov. 10, 1958, copper
still to receive preferential treatment. An inadequate items, including copper scrap and copper-base scrap
supply condition was prevalent from 1954 to 1956. were removed from the Dept. of Commerce positive
Due to the continuing shortage of copper, quantity list of items requiring export licenses and placed on
export controls were maintained on refined copper the general list for export to all destinations, except
through the third quarter of 1956 and on copper scrap Hong Kong, Macao and the Sino-Soviet bloc. At the
through the third quarter of 1957. same time, after a seven-year suspension, the excise
tax on copper imports was reimposed on July 1. The

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effective rate was 1.7 cents per pound. On June 11, (1) release of 200,000 tons of copper from the
1958, the President signed a bill to continue National stockpile,
suspension of duties on metal scrap to June 30, 1959.
In 1959, the United States was affected by the longest (2) control of exports of copper and copper scrap
copper mine labor strike to date, lasting 6 months. As for an indefinite period to conserve domestic
a result, mine output fell 16% from the previous year, supply,
and the substantial loss in production created the
need for a larger quantity of imports. On Feb 20, (3) legislation to suspend the 1.7 cent-per-pound
1959, the Dept. of Commerce reimposed controls on import duty on copper, to encourage a greater
all copper exports; shippers were required to declare inflow of metal, and
destinations of all shipments except those to Canada.
(4) imposition of higher margin requirements on
In 1960, imports and exports were almost equal, and copper trading by directors of the COMEX to
in 1961, the United States had again become a net lessen speculation in the metal.
exporter of copper materials. The priorities provided
for under the Defense Materials System (DMS), which Copper scrap export limits were put at 30,000 tons in
was basically similar to the Controlled Materials Plan 1966 to all countries except Canada. The scrap limit
(CMP) administered during both World War II and the applied to the scrap content containing more than
Korean conflict, were in place in 1962, despite a 40% copper and was based on a company’s recent
relatively easy supply situation. Nevertheless, exports trade volume. Copper exports other than scrap were
of scrap in 1960 expanded sixfold. Stocks of copper not limited.
scrap at mills dropped 15% during 1960, as a result of
heavy buying from foreign buyers in Japan and Labor strikes in 1967 reduced U.S. mine capacity by
Western Europe. West Germany received about one- 80% and lasted for nine months. Before the end of
third of the total. December in 1967, shortages and the increasing cost
of copper had forced some manufacturers to stop
By 1960, the Government National Stockpile of production. There were also supply restraints from
copper contained more than 1 million tons of copper. Central Africa, Chile and Peru, owing largely to labor
With the onset of escalation of the Vietnam War, disputes. Some 176,000 tons of refined copper was
however, much of this copper would be released. Sale distributed from the National Stockpile during the first
of 590,000 tons of copper from the strategic stockpile nine months of 1967, but it was insufficient to
was authorized by legislation in 1965 and 1966, immediately stem the shortages. Even so, during the
reducing the stockpile to about 228,000 tons by 1968. first six months of 1967, U.S. export controls permitted
The remainder was released in 1974. Only 20,000 the exportation of 16,500 tons of copper scrap, 25,000
tons of refined copper remained in the National tons of refined copper and 10,000 tons of copper
Stockpile until 1993, when it was all sold. contained in copper-base alloy and copper
semifabricated products and master alloys. A virtual
The copper industry established new records, as embargo had been in place on exports of domestic
demand began to accelerate late in 1963 and origin copper since Jan. 20, 1966. The strikes, which
continued strong through 1964. Exports of copper began on July 15, 1967, rapidly disrupted normal
scrap during 1964 increased more than threefold, and relations between the mines and smelters and
exports of copper-base scrap almost doubled. Japan refineries. The mines began to stockpile concentrate
received 44% of the copper scrap and 77% of the to the point that production was threatened. To relieve
copper-base scrap exported. Copper continued in this situation, export regulations for mine and smelter
tight supply through 1965, despite an increase of 4% products were amended to permit licensing for export.
in free world mine production. The record production The licensing arrangement was later modified to
was attained in spite of strikes in Chile, losing an permit the exportation of scrap that could not be
estimated 100,000 tons of potential production. processed in the United States for technical or
Substantial quantities of copper also were released economic reasons or because of the strike. Scrap
from the Government National Stockpile. Yet supply exports were concentrated in the last five months of
was inadequate to meet record demand for metal 1967, making the annual amount near that for 1966. A
caused by unprecedented prosperity in the free world 50% increase in exports of copper-base alloy scrap
and by military action in Vietnam. accounted for most of the 1967 increase in alloy
exports.
On Nov. 17, 1965, the Government announced a 4-
point program to reduce inflationary pressures on the At the beginning of 1968, more than 90% of the
price of copper that might impair the defense effort in domestic copper industry was closed by continuation
Vietnam. The program called for: of the labor strike that started in July 1967. A further
13,800 was withdrawn from the National Stockpile,

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89
leaving only 201,300 tons in the stockpile at year-end. and members of these societies filed short supply
On resumption of operations after settlement of the petition under the Export Administration Act,
copper industry strike, export controls, administered requesting imposition of monitors and controls on the
by the Office of Export Control, and producer set- export of copper-based scrap. The Institute of Scrap
asides, administered by the Business and Defense Recycling Industries, Inc. (ISRI) and its broker and
Services Administration (BDSA), both in the U.S. scrap trader members took an opposition stand to the
Department of Commerce, again became effective. request stating that restricting exports would have
eliminated the market for a large proportion of scrap
Export licensing quotas for the second half of 1968 that was not likely to be used domestically. Underlying
were set at 25,000 tons of copper-base scrap. Export the petition was the belief by U.S. copper scrap
quotas were also set for refined copper, consumers that China had been applying unfair trade
semifabricated productions and other copper practices and essentially was cornering the market for
materials. Owing to the large increase in exports of copper scrap, Depressed copper prices and the unfair
copper scrap to Canada during 1969, Canada was competition for domestic scrap by exporters to China
added to the quota list near year-end and allotted only since 1999 had placed some scrap processing (wire
2,400 tons for the year. Despite these restrictions, choppers, secondary smelters and others) and
exports of unalloyed copper scrap were 34,000 tons, consuming (brass mills etc.) facilities at a competitive
an increase of almost 100% from those of 1967, and disadvantage. Ingot production dropped sharply by
exports of copper alloy scrap were 86,000 tons, up 2002, (see Figure 7, this report) and by late 2003,
32% from 1967 levels. Export controls on copper scrap supplies were so tight as to cause some local
products continued through 1969. The export quota mills and wire choppers to cut back capacity or to
on refined copper from domestic primary sources was close. The Export Administration Act allows the U.S.
set at 50,000 tons, and on scrap it was 60,000 tons of Government to impose export controls on scrap
contained copper. metals under specific circumstances when scrap
availability is an issue, or where the price is
In 1970, the domestic copper industry experienced significantly impacting inflation. ISRI felt that neither of
record high production, reduced consumption and an these situations were the case and stated that it would
increase in copper stocks. Considerable expansion in have preferred to have brought redress through the
world copper production capacity, coupled with Section 301 of the trade law for trade violations
reduced demand in the United States, resulted in a (American Recycler, Sept 2004). The Commerce
dramatic reversal in copper markets, from one of short Department, after a hearing in May 19, 2004 where all
supply to one of surplus supply. This reversal was parties testified, issued its decision in August, 2004
reflected in a price increase in April followed by price citing that there was no need for controls, or
reductions in October and December 1970. The monitoring of exports of copper-based scrap. As
improved supply situation led to removal of the 1965 copper supplies tightened, China began institutional
export controls by September 1970. At this point, a changes of its own in 2004 that would only temporarily
total of 260,467 short tons of copper remained in the ease the tight supply situation in the United States.
stockpile. Even so, scrap exports to the Far East continued
unabated at high rates through 2007. See further
World copper was in oversupply over most of the discussions elsewhere in this paper.
period 1975-1988. The excess world copper
inventories, which had accumulated over the 1970s, The marked decrease in U. S. industrial consumption
were finally worked down by 1988 to below 1 month of of copper is visible on the graph shown in Figure 15
world supply. Increased World industrial demand was since 1999, and is coincidental to the massive export
underway by the mid-1990s, and the new mine of scrap supplies to the Far East. U.S. import reliance
capacity that had been under construction since the for copper also increased over this period from 2% in
early 1990s had not yet been put in place. All concern 1993 to over 40% in 2006, owing to the significant
for potential shortages of scrap and of copper increase of copper-based imports into the United
disappeared, and the remainder of the U.S. copper States and concurrent decrease in U.S. mine
stockpile was sold off in 1993. production and availability of secondary material
recycle. This has occurred despite the ongoing needs
On April 7, 2004, the Copper and Brass Fabricators of the current war in Iraq and a booming housing cycle
Council (CBFC), the Non-Ferrous Founders’ Society until mid-2007.

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APPENDIX B (4) Metal Banks, Philadelphia, Pennsylvania
Discovery 6/1/77. On the Final NPL, ROD
12/31/97, EPA/541/R-98/012. ESD 12/15/00.
Contaminants include metals as well as acids,
Superfund Sites dioxins and PCBs. Starting in 1962, the site was
used for scrap metal storage, then from 1968-
1973, it was used for transformer salvage.
The following secondary copper-base processing
Copper wire was burned to remove insulation
plants have been found on EPA’s computerized
1968-1972. In the southern area, scrap metals
CERCLIS.
were recovered and scrap storage continued
until 1985, and transformer salvage operations
stopped in 1973. Final design almost complete,
Listed on the National Priorities List construction should start Fall 2006.
(NPL):
(5) Tex-Tin Corp. (Gulf Chemical & Metallurgical).
(1) Jacks Creek/Sitkin Smelting and Refinery, Texas City, Texas Currently on the Final NPL.
Lewistown, Pennsylvania ROD 9/30/97 ESD Discovery 11/1979. Final NPL on 9/18/98. ROD
4/19/01.(EPA/541/R-97/087 9/29/2000. Consent decree 10/2000. Was a
copper scrap fire refinery (1989-1991), and a tin
Contaminants listed: Sb, Cd, Cu, Pb, Se, Ag, Zn, smelter earlier.
dioxins and polychlorinated biphenyls (PCBs),
Sitkin Smelting was an active ingot maker at the (6) Eastern Diversified Metals. Hometown,
site from 1958 through 1977, when it declared Pennsylvania. Currently on the Final NPL. ROD
bankruptcy. About 110 parties have been named 3/91, 7/92, 9/93. From 1966-1977, copper and
responsible parties (PRPs) owing to shipments of aluminum was reclaimed from wire and cable.
materials to this firm for treatment. Early phase I Contaminants include metals, PCBs and dioxins.
cleanup was completed August 9, 2001. On Stripping waste, plastic fluff, was disposed
November 18, 2004, the pre-final inspection was behind facility in 40-ft high mounds. Nassau
done and the EPA finished the Preliminary Metals named as a PRP for cleanup.
Close-Out Report for Jacks Creek on December
23, 2004. (7) C&D Recycling. Foster Township, Pennsylvania.
Currently on Final NPL. ROD 9/30/1992.
Major remedies for the site included: excavation Contaminants include Cu, Sb, Pb and other
of soils with treatment off site; excavation and metals. C&D recovered copper and/or lead from
onsite consolidation of waste pile materials and cable or scrap metal in 5 onsite furnaces used to
soils; vacuum dredging and consolidation of burn cable from the 1960’s to 1980’s. The
Jacks Creek sediments; covering and capping of furnaces have been demolished. Starting in
soils, sediments and waste piles; covering and 1998, Lucent Tech. stabilized and disposed off
revegetation of all excavated areas and site 90,000 tons of contaminated soils and
demolition of unsound buildings. Groundwater sediment. The site has been regraded and
and surface waters will undergo long-term seeded.
monitoring.
(8) Franklin Slag Pile. Philadelphia, PA. Final rule
(2) American Brass, Headland, Alabama. Discovery NPL on 09/25/2002. EPA has stablized the site
7/25/96. Final listing on NPL 5/10/99. This was and there is no current threat to the environment.
an active ingot maker until 1996, when the plant The slag pile is now covered with a thick plastic
closed. Emergency soil and brick removal was cover. The next step will be to complete
done in 1996-1997. Remedial Investigation and propose a plan for
cleanup. Associated with Franklin Smelter.
(3) Kearsarge Metallurgical Corp., Conway, New
Hampshire. Discovery 11/1/82. ROD 9/28/90. (9) Franklin Burn Site. Franklin, New Jersey. Final
Currently on the Final NPL. Kearsarge was a NPL date 6/17/96. Copper wire was burned to
nonferrous foundry. High on the contamination remove plastic coatings and other electrical
list is chromium, HF acid, organic compounds, components for the recovery and sale of copper.
ceramics and flammable liquids. The nine-acre The burning resulted in ash piles containing
site is located within the 100-year floodplain of hazardous substances. Burning ceased in 1988.
the Saco River. The ground water in the upper
aquifer under the site was determined to be (10) Curcio Scrap Metal. Inc. Bergen County,
contaminated. New Jersey.

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91
 Final NPL date 07/01/87. Burn site for scrap iron, assessment 6/17/85. Not on the NPL. Deferred
copper and other metals. While cutting 50 to RCRA.
electrical transformers in 1982, PCBs containing
oil spilled on the ground. Some 3,000 people live (12) Prier Brass Mfg. Co., Kansas City, Missouri.
close by and the site is located above the Discovery 12/18/86. Negotiation 4/17/97.
Brunswick Aquifer. Final remedial design report Consent agreement 5/8/97. Not on the NPL.
detailed March 1993. Long-term monitoring
started on March 2000. (13) Bridgeport Brass, Norwalk, Connecticut.
Discovery 1/1/87. Site inspection 6/7/93. Not on
the NPL.

(14) Seymour Brass Turning, Seymour, Connecticut.

Not listed on the NPL: Discovery 12/13/88. Site inspection 4/23/93. Not
on the NPL.

(1) Franklin Smelting and Refining, Philadelphia, (15) Seymour Specialty Wire, Seymour, Connecticut.
Pennsylvania. Not on the NPL. Franklin was an Discovery 5/16/89. Site inspection 11/07/94. Not
active secondary smelter for years at this site. on the NPL.
The plant closed in 1998.
(16) Chase Brass and Copper, Waterbury,
(2) Talco Metals, Philadelphia, Pennsylvania. No Connecticut. Discovery 1/1/81. Site inspection
action listed. 6/25/85. Not on the NPL.

(3) Shenango, Inc, Sharpsville, Pennsylvania. (17) Phelps Dodge Refining Corp. Maspeth, New
Discovery York. Not on the NPL. Discovery 5/79. Site
3/29/1985. Site inspection 10/17/89. inspection 8/83. Closed copper refinery.

(4) Eastern Smelting and Refining (Metals Refining (18) Nassau Recycle Corp. Staten Island, New York.
Co.), Los Angeles, California Discovery 2/15/96. Not on the NPL. Discovery 1/80. Proposal to NPL
Prelim. Assessment 6/30/98. Not on the NPL. 2/92. Processed copper wire scrap.

(5) Anaconda Industries Brass, Detroit, Michigan. (19) National Smelting & Refining Co. Atlanta,
Discovery 7/29/92, Prelim. Assessment 9/26/96. Georgia. Not on the NPL. Discovery 8/80. Admin
Not on the NPL. order on consent 6/89. Vol. Cost recovery 3/92.

(6) Kocide Chemical, Casa Grande, AZ. Not on the (20) CMX., Los Angeles, California. Not on the NPL.
NPL Discovery 1/87. .Site reassessment 6/2000. Discovery, 12/07/1999. Preliminary assessment
Was a copper sulfate plant. Deferred to RCRA. start 8/15/2000, completed 6/29/2001. This plant
is an active ingot maker.
(7) Ansonia Copper & Brass, Waterbury,
Connecticut. Discovery 1/1/81. Preliminary (21) Federal Metals. Los Angeles, California. Not on
assessment 8/30/86. Not on the NPL. the NPL. Discovery 1/1/1987. Site inspection
9/24/1991. Site reassessment completed
(8) Anaconda American Brass. Ansonia, 6/7/2001.
Connecticut. Not on the NPL. Discovery 1/81.
Site inspection 10/91. (22) Anchor Metals. Anniston, Alabama. Not on the
NPL. Assessment complete. Decision needed.
(9) Revere Copper & Brass Inc., Clinton, Illinois.
Discovery 9/1/80. Site inspection 10/24/90. Not (23) Lee Brothers Brass Foundry. Anniston, Alabama.
on the NPL. Not on the NPL. Discovery 5/1/2000, Preliminary
assessment 9/30/2000, Site inspection
(10) Vulcan-Louisville Smelting Co. (Lavin & 10/18/2001.
Sons),(North Chicago Refiners & Smelters),
North Chicago, Illinois. Discovery 8/29/90. (24) Chicago Copper and Chemical Co. Calument
Expanded site inspection 8/1/95. Not on the NPL. Park, Illinois. Not on NPL.
PPA assessment 5/19/2000. Unilateral admin.
order 9/21/2000. This plant closed in 2003. (25) C&P Chemical Company. Sumter, South
Carolina. South Carolina Superfund site.
(11) Southwire Co. Copper Division., Carrolton, Produces copper chemicals.
Georgia Discovery 8/01/80. Preliminary

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92
(26) Sauget Area 1. Sauget and Cahokia, Illinois. Site (6) Brush Wellman, Inc. Elmore, Ohio. Discovery
was proposed to the NPL 9/13/2001. Site 10/01/1980. Archive site 3/28/1990.
comprises 7 sources including wastewater from
Cerro Copper Co. and Monsanto Chemical Co. (7) Ohio Brass Company. Barberton, Ohio.
Discovery 6/28/1984. Archive site 9/26/1995.
(27) Ward Transformer. Raleigh, North Carolina.
Proposed for the NPL 4/30/2003. Transformer (8) Federated Fry. San Francisco, California.
parts were burned in open air to reclaim copper. Discovery 6/01/1988. Archive site 11/21/1988.
An incinerator is currently used.
(9) Cerro Metal Prod. California Works. Newark,
California. Discovery 12/01/1979. Archive site
Archived Sites: Archive status indicates that, to 7/20/1990.
the best of EPA’s knowledge, Superfund has
completed its assessment and has determined (10) Cerro Metal Prod. Plant #1, Bellefonte,
no further steps will be taken to list that site on Pennsylvania. Discovery 6/11/1991. Assessment
the NPL. 12/15/1992.

(11) H. Kramer & Co. El Segundo, California.

Unilateral Admin. Order 7/7/1988. PRP Removal
(1) Lee Brass Company. Anniston, Alabama. 11//7/1990. Admin. Records 3/26/1992. Archive
Deferred to RCRA. Archive site 12/23/1996. site 7/24/2000. Abandoned foundry.
(2) Monarch Foundary. Plano, Illinois. Not on the (12) SCM Corp. Chem. Metallurgical. Ashtabula,
NPL. ESI ongoing. Discovery 8/03/1991, Site Ohio. Archived 12/02/1991.
inspection 9/19/1994.
(13) Kearny Smelting & Refining. 936 Harrison Ave,
(3) United Refining & Smelting Co. Franklin Park. Kearny, New Jersey. Discovery 6/27/1986.
Illinois. Discovery 8/01/1980. Archive Site Archive Site 9/26/1994. NFRAP status.
10/19/1990.
(14) Chemetco. Hartford, Illinois. Not on the NPL.
(4) Olin Corp Main PLT. East Alton, Illinois. Discovery 8/1980, Archived 11/87.
Discovery 4/01/1979. Archive site 7/09/1987.

(5) Olin Corp. Zone 17 Plant. East Alton, Illinois.

Deferred to RCRA. Archive site 12/08/1995.

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93
LIST OF REFERENCES 16. Kirk-Othmer Encyclopedia of Chemical Technology,
1997. Vol 20, Recycling (Nonferrous metals), p. 1111-
1116.

1. McMahon, A.D., 1965, Copper, A Materials Survey. IC 17. U.S. Dept. of Health, Education and Welfare, 1969, Air
8225, U.S. Bureau of Mines, 340 p. Pollution Aspects of Brass and Bronze Smelting and
Refining Industry. Publication No. AP-58, Nov. 1969
2. Jolly, Janice L.W., 1993, Copper, A Chapter in National Air Pollution Control Admin., Raleigh, NC.
Recycled Metals in the United States, Special
Publication, October 1993, U.S. Bureau of Mines, p. 18. U.S. EPA, 1977, Emission Factors and Emission
17-22. Source Information for Primary and Secondary Copper
Smelters, Publication No. EPA-450/3-051, Dec. 1977,
3. Jolly, Janice L.W. 1985, Copper, A Chapter in Mineral Research Triangle Park, NC.
Facts and Problems, U.S. Bureau of Mines
19. Fukubayashi, H.H., et al., Recovery of Zinc and Lead
4. U.S. Bureau of Mines and U.S. Geological Survey, from Brass Smelter Dust, RI No. 7880, Bureau of
Minerals Yearbooks, 1906-2007. Chapter on Copper Mines, U.S. Dept. of Interior, Wash. D. C., 1974.
and Secondary Materials; and, Mineral Industry
Surveys, Copper, various issues. 20. American Metal Market, 1999, Group wants copper cut
from toxics report: v. 107, no. 171, Sept. 3, p. 7.
5. Edelstein, Daniel, 1995-2007, Chapters on Copper
and Secondary Materials; Minerals Yearbook and 21. EPA document 450/4-90-003
Mineral Industry Survey, various monthly and annual
issues, U.S. Geological Survey. 22. EPA CERCLIS database (http://www.epa.gov)

6. Jolly, James H., 1993, Zinc, A Chapter in Recycled 23. Test Methods for Evaluating solid Waste,
Metals in the United States, Special Publication, Physical/Chemical Methods — SW-846. Available on
October 1993, U.S. Bureau of Mines. P. 69-72. internet at:
http://www.epa.gov/sw-846/main.htm
7. Plachy, Joseph, 1997, Zinc, a section in Recycling—
Metals, Special Publication, Minerals Information. P. 24. Rosenbaum, Wayne, ISO 14000: News & Views,
10. http://www.lawinfo.com.

8. Plachy, Joseph, 1994-2005, Chapters on Zinc and 25. OSHA Review Commission Decisions,
Secondary Materials, Minerals Yearbooks (1994-2003) http://www.osha-slc.gov
and Mineral Industry Surveys, U.S. Geological Survey.
26. OSHA Industrial Hygiene Profiles database,
9. Spendlove, Max J., 1961, Methods of Producing http://www.ergweb.com
Secondary Copper, U.S. Bureau of Mines, IC 8002,.
41 pp. 27. EPA, RCRA, Superfund & EPCRA Hotline Training
Module, EPA 540-R-98-028, Updated Feb. 1998.
10. Carrillo, F.W., Hibpshman, M.H., and Rosenkranz Introduction to: Superfund Liability, Enforcement, and
R.D., 1974, Recovery of Secondary Copper and Zinc Settlements,
in the United States. IC 8622, U.S. Bureau of Mines, (http://www.epa.gov)
58 p.
28. U.S. EPA Office of Solid Waste, 1995, Applicability of
11. International Copper Study Group, Copper Bulletin, the Toxicity characteristic Leaching Procedure to
Monthly Statistical Publication, 1995-2007. Lisbon, Mineral Processing Wastes, Dec. 1995.
Portugal.
29. Battelle Columbus Laboratories, 1975. Energy Use
12. USITC, Internet site and U.S. Trade Database, Patterns in Metallurgical and Nonmetallic Mineral
http://www.itds.treas.gov processing, U.S. Bureau of Mines Open File Report
80-75.
13. Institute of Scrap Recycling Industries, Inc., Scrap
Specifications Circular 1991, Guidelines for Ferrous 30. Kusik and Kenahan, 1978, Energy Use. IC 8781, U.S.
Scrap, Nonferrous Scrap, Paper Stock, Plastic Scrap, Bureau of Mines.
1325 G St., N. W., Washington, D.C. 20005, p.2-13.
31. Brooks, C.S., 1984, Metal Recovery from Waste
14. Copper Development Association, Annual Data 2005, Sludges, Proceedings of the 39th Industrial Waste
Copper Supply & Consumption, 1982-2005. Conference, Purdue Univ., May 8,9,10, 1984.
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