2013 Technical Report

The U.S. Copper-base Scrap Industry and Its By-products

www.copper.org
A1309-12/13
The U.S. Copper-base Scrap Industry
And Its By-products

An Overview

Thirteenth
Edition, 2013

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 historical and current 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 the last ten years. While the coverage is
not comprehensive, a brief mention is made of the many problems impacting the health of the industry.
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 decade has been particularly
difficult, given the restrictions within which they have operated, the potential for new restrictions, and the
variable copper markets.

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, the
Late Alan Silberof 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, and continues to be of great assistance in
providing world copper industry statistics. The research for this report was supported by the Copper
Development Association. This thirteenth edition presents updated data tables and observations made
since the first report was written in 1999. It is hoped that the historical perspective presented will help
in understanding future events and making new decisions.

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 ....................................................................................................6
World Copper Consumption and Production.............................................................6
World Trade in Copper Scrap..................................................................................10
World Production and Trade in Copper Alloy Ingot .................................................13
Domestic Industry Perspectives............................................................................................14
Domestic Uses for Copper ......................................................................................14
U.S. Consumption of Copper ..................................................................................15
U.S. Trade in Copper and Copper Alloy Scrap .......................................................17
U.S. Export Controls on Scrap ................................................................................18
Products and By-products Produced from Scrap..................................................................18
Wrought Copper and Copper Alloys........................................................................18
Brass and Bronze Ingots .........................................................................................19
Refined Copper .......................................................................................................20
Copper Anodes for Plating ......................................................................................20
Black Copper...........................................................................................................20
Copper Chemicals and Powders .............................................................................20
Secondary Copper By-products ..............................................................................21
Baghouse Dusts ......................................................................................................22
Other Metal Recovery .............................................................................................22
Items that Go to the Landfill ....................................................................................22
Description of the U.S. Secondary Industry ..........................................................................22
Brass Mills ...............................................................................................................24
Foundries ................................................................................................................25
Ingot Makers............................................................................................................25
Secondary Smelters and Refiners...........................................................................25
Hydrometallurgical Plants........................................................................................25
Metal Finishing Facilities .........................................................................................65
Flow of Materials ...................................................................................................................26
Summary of Scrap Flow ..........................................................................................26

CHAPTER 2 — OVERVIEW OF SCRAP SOURCES AND TYPES

Scrap Sources and Types.....................................................................................................28
EPA Secondary Product Definitions .....................................................................................28
Consumption by Scrap Type.................................................................................................29
Volumes of Scrap Generated................................................................................................31
Use of Home Scrap...............................................................................................................33
At Brass and Wire Mills ...........................................................................................33
At Secondary Smelters and Refiners ......................................................................34
At Foundries ............................................................................................................34
Use of Purchased Scrap .......................................................................................................34
Life Cycles and the Theoretical Resource for Scrap.............................................................34
Resource Theory and Calculations .........................................................................36

CHAPTER 3 — OVERVIEW OF SCRAP PREPARATION, MELTING AND PROCESSING

Scrap Preparation .................................................................................................................41
Laboratory Testing ................................................................................................................43
Energy Use ...........................................................................................................................43
Scrap Preparation ...................................................................................................43
Melting Scrap ..........................................................................................................43
Scrap Melting and Processing ..............................................................................................43
Melt Control .............................................................................................................44
Drosses and Dross Formation.................................................................................44

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 Melt Covers (Fluxes) ...............................................................................................45
Use of Deoxidizers ..................................................................................................45
Vapor Losses ..........................................................................................................46
Particulate Matter and Fugitive Emissions ..............................................................46
Furnaces ...............................................................................................................................46
Arc Furnaces ...........................................................................................................47
ASARCO Furnaces .................................................................................................47
Crucible Furnaces ...................................................................................................47
Blast Furnace, Cupola.............................................................................................47
Reverberatory Furnaces..........................................................................................48
Converters ...............................................................................................................48
Rotary Furnaces ......................................................................................................48
Low-frequency Induction Furnaces .........................................................................48
Sweating ...............................................................................................................................49

CHAPTER 4 — ENVIRONMENTAL OVERVIEW

Basel Convention ..................................................................................................................50
OECD Rulings .........................................................................................................50
CERCLA Overview ...............................................................................................................51
Hazard Ranking System (HRS)...............................................................................52
Resource Conservation and Recovery Act ...........................................................................52
Toxicity Characteristic Leaching Procedure (TCLP) .............................................................53
Suggested Improvements for the TCLP ..................................................................53
Multiple Extraction Procedure (MEP) ......................................................................54
Hazardous Wastes................................................................................................................55
Toxic Release Inventory System (TRIS) and Other Databases............................................55
Lead in the Workplace Directives (OSHA) ............................................................................55
Clean Air Act Ruling ..............................................................................................................57

CHAPTER 5 — PROBLEMS AND SOLUTIONS

The Problems........................................................................................................................59
Industry Solutions .................................................................................................................61
Process Recovery Corp. .........................................................................................61
Management Systems and ISO Standards .............................................................61
Electronic Scrap……………………………………………….…………...…….………. 62
Lead in Potable Water……………………………………………………………...……63
Government Solutions………………………………………………………………….……..…...63
Radioactive Metals………………………………………………………….…..……….65
Material Theft…………………………………………………………...….……...……..65

ILLUSTRATIONS:

CHAPTER 1 FIGURES
Figure 1. World Copper Inventory Trends..........................................................................................6
Figure 2. World Copper Recovery from All Sources and Percent Copper from Scrap1976-2012 …..7
Figure 3. World Consumption of Copper of Direct Melt and Refined Scrap, by Region1976-2012....8
Figure 4. Trade in Copper and Copper Alloy Scrap, by World Region1989-2011 ...........................10
Figure 5. U.S. Total Copper Consumption, Including All Scrap 1966-2012……………………..…...14
Figure 6. Trends in U.S. Net Export and Consumption
of Copper in Copper-base Scrap1981-2012.................................................................15
Figure 7. U.S. Copper Alloy Ingot Production, by Ingot Group1984-2011 .......................................19
Figure 8. Trends in U.S. Copper Smelter and Refinery Capacities .................................................23
Figure 9. U.S. Copper and Copper Alloy Purchased Scrap Flow Chart for 2011 ............................27

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CHAPTER 2 FIGURES
Figure 10. U.S. Copper and Copper Alloy Scrap Consumption, by General Alloy Group ................30
Figure 11. U.S. and World Scrap Resource, Pool of Copper Materials in Use .................................35
Figure 12. U.S. Copper Resource for Old Scrap, Pool of Copper Materials in Use1939-2012 ........37
Figure 13. Cumulative Old Scrap Copper, In the United States1959-2012 ......................................39
Figure 14. U.S. Industrial Copper Consumption Trends and Response
to Major Historical Events ...........................................................................................92

TABLES:

CHAPTER 1 TABLES
Table 1. LME, COMEX and U. S. Refined, Scrap and Ingot Prices ................................................66
Table 2. World Copper Consumption. Direct Melt and Refined Scrap, and Refined Copper
A. World Copper Recovery from All Sources ..................................................................67
B. World Production of Refined Copper by Source .........................................................68
C. World Consumption of Copper in Direct Melt Scrap ..................................................69
D. World Recovery of Copper from Copper-base Scrap, by Country and Area .............70
Table 3. World Copper and Copper Alloy Scrap Exports ................................................................71
Table 4. World Copper and Copper Alloy Scrap Imports ...............................................................72
Table 5. World Production of Copper and Copper Alloy Ingots .......................................................73
Table 5A. World Production of Copper and Copper Alloy Foundry Products ....................................74
Table 5B. World Copper, Copper Alloy and Master Alloy Ingot Imports ............................................75
Table 5C. World Copper, Copper Alloy and Master Alloy Ingot Exports............................................75
Table 6. U.S. and World Refined Copper Consumption and U.S. Copper From Scrap ..................76
Table 6A. U.S. Cumulative Copper Calculations ...............................................................................77
Table 6B. Estimation of the Recycling Input Ratio (RIR) and Recovery Ratio
for the United States.....................................................................................................78
Table 7. U.S. Production of Refined Copper, by Source .................................................................79
Table 8. U.S. Exports and Imports of Copper and Copper Alloy Scrap...........................................80
Table 8A. U.S. Domestic Exports of Copper and Copper Alloy Scrap, by type .................................80
Table 9. U.S. Trade and Consumption of Copper Ash and Residues
and Zinc Products from Scrap.. .....................................................................................81
Table 10. Ingots, Foundry Castings, Brass- and Wire-Mill Semis and Copper Sulfate
Production in the United States .....................................................................................82
Table 10A. U.S. Exports of Copper and Copper Alloy Semis, and Copper sulfate. Powder
and Hydroxides..............................................................................................................82
Table 10B U.S. Imports of Copper and Copper Alloy Semis, and Copper Sulfate, Powder
and Copper Hydroxides .................................................................................................82
Table 11. Standard Designations for Cast Copper Alloys .................................................................83
Table 12. Copper Recovered from Scrap in the United States and Form of Recovery .....................83
Table 13. List of U.S. Primary Brass and Tube Mills .........................................................................84
Table 14. List of U.S. Ingot makers, Secondary Smelters and Refiners, and Secondary
Chemical and Hydrometallurgical Plants .......................................................................85

CHAPTER 2 TABLES
Table 15. Copper and Copper Alloy Scrap Types, Showing General Range in Compositions ..........86
Table 16. Principal U.S. Scrap Source Materials for Copper .............................................................87
Table 17A. U.S. Copper Scrap and Copper Alloy Consumption (1977-1994)………….…………….…87
Table 17B. U.S. Copper Scrap and Copper Alloy Consumption (1995-2011) ......................................88
Table 18. Estimated Secondary By-products, by Plant-Type Sector..................................................89

CHAPTER 3 TABLES
Table 19. Particulate Emission Factors for Furnaces Used in Secondary Copper Smelting
and Alloying Process .....................................................................................................90

APPENDIX A Historical Review of U.S. Export Controls on Copper-base Scrap .....................................91

APPENDIX B Superfund Sites .................................................................................................................95
LIST OF REFERENCES ..................................................................................................................................98

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EXECUTIVE SUMMARY Shortages persisted despite efforts by the major
copper producers to bring mines back on stream, or
start new mines, to increase production. Labor strikes,
The worldwide industrial recession, which began
lower ore grades and other production problems
suddenly in 2008, continued through late 2009. The
seemed to plague the industry. The supply/demand
economy was somewhat improved through much of
deficit for 2005 was 73,000 tons according to the
2010 and 2011. By mid-year 2012, however, traders
International Copper Study Group (ICSG). At the end
were expecting the market to trend down because of a
of December 2006, total world copper inventories,
number of factors outside of North America. Concern
were 1.1 million tons and were about 23% less than
over the shaky European market worried many
that required to supply the world for one month. Owing
recyclers. Economic concerns that started in Greece
to the release of unknown, but apparently significant,
spread to Spain, Italy and France. In addition, the
quantities of copper from the Chinese strategic
Chinese economy continued to slow, adding to the
stockpile, world copper supplies were partially
short term negative outlook for nonferrous scrap
ameliorated during the latter part of 2006, and prices
markets. While metal prices and the stock market
began to soften. By yearend 2007, visible world
recovered gradually from late 2009 onward, U.S.
copper stocks were estimated by the ICSG to be
industrial activity generally lagged over much of the
around 970,000 tons, down by about 105,000 tons
period.
from that of yearend 2006 (ICSG, Nov. 2011). These
inventories represented about 1.5 weeks of average
Meanwhile, China’s higher consumption in 2009 and
world copper consumption, and well below the four-
2010 was largely supported by government policy.
week level (1.4 million tons) for world consumption
Metal intensive products were also helped by policy
that by many is considered to be “normal”, or in
measures. In 2009, substantial parts of China’s
balance. Inventories increased during early 2008 to
stimulus package were targeted at infrastructure.
around 1.26 million tons. A delicate balance between
The end result was that China’s demand picked up
supply and demand persisted. By October 2012, the
much of the “slack” for reduced demand in most of
ICSG reported refined stocks at 1.1 million tons, well
the rest of the world. Even so, the Chinese
below one month’s average consumption of 1,683
government showed signs of concern about an
million tons per month.
overheated economy when it raised interest rates at
mid-year 2010. Toward yearend 2010 and in 2011,
Copper prices were extremely volatile and variable
China’s demand was slower as indicated by lower
over the periods 2007 through 2011. By January
imports, rising stockpiles, falling premiums, rising
2009, the LME price had retreated from the lofty highs
treatment fees and higher scrap supply. Higher
of 2007 and early 2008 to a low of $1.46 per pound.
copper prices over much of the 2009-2011 periods
As a result of the continued pressure on available
prompted worries about “demand destruction” in an
supplies through 2010, the average LME price for
overheated Chinese economy. By 2010, China
refined copper was in the mid-$3 range through most
tightened monetary policy in an attempt to dampen
of the year, reaching $4.45 per pound by yearend.
excessive stockpiling and other speculative activities.
The weaker dollar and the speculative pressure of
Chinese buying were largely responsible for the rise in
Even so, copper scrap concluded 2012 on a
prices. However, it also was revealed late in 2010
somewhat positive note. After slumping during the
that a brokerage firm, J.P. Morgan, had purchased
middle half of the year, interest in copper scrap
nearly 90% of the copper inventories on the LME,
increased at the end of 2012. specially from buyers for
ostensibly to establish a new copper exchanged-
Chinese consumers. These buyers were interested in
traded-fund (ETF). Several other firms were
adding to their inventories, contributing to the
considering similar moves. By mid-year 2012,
movement and price of copper throughout Western
however, the mood of the market began to change.
Europe. According to a Recycling Today report (Jan
The average LME refined copper price for 2012 was
2013), the German copper producer and copper
$3.61 per pound.
scrap recycler Aurubis reported an increase in sales
for 2012 and was expressing a more bullish outlook
In August, and September of 2008, despite a series of
for 2013. Regarding copper scrap, the company
financial “rescue” packages by the U.S. government,
noted that its availability had improved through 2012,
the credit crises abruptly stifled industry throughout
leading to higher utilization rates for the group’s
the world. On the major stock exchanges, the share
recycling capacities. In general, Aurubis noted that
values for the copper mining companies had also
the copper scrap market was good during its
plummeted by up to 80%, within a few short weeks.
2011/2012 fiscal year.
Even though basic industrial growth continued to
languish, the U.S. stock exchange prices began to
Looking back historically, world copper was in short
gradually improve from 2009 through 2010, even as
supply through most of the period, 2005 through 2008.
inventories were seen as rising over the period,

1
World inventories, while historically low, continued to U.S. scrap processors and their U.S. customers
rise through 2011. Inventories had increased from (brass mills, ingot makers and foundries) remained at
970,000 tons in 2007 to about 1.161 million tons at a critical point through 2012. Scrap supplies for
yearend 2008 (ICSG, October 2010). Total world domestic users since 1999 remained tight and some
inventories at yearend 2009 were 1.35 million tons. qualities (such as auto radiators) were difficult to
However, at the end of October, 2012, total obtain. Price spreads varied, but owing to higher
inventories held by the exchanges, producers and processing costs (labor, environmental, energy and
consumers were marginally lower at 1.1 million tons. taxes), and high competitive scrap exports, domestic
These levels were well below one month’s world markets remained difficult. Tight scrap supplies were
consumption. To put this into perspective, this level driving prices over much of the past 12 years. China,
compares with the 1.69 million tons of refined copper South Korea and India continued to be large importers
that the ICSG estimated to be consumed by the world of U.S. and European scrap.
in October 2012.
For a pictorial illustration of U.S. refined copper
Looking back to the effects of the supply buildup consumption over time, one has only to take a look at
between 1998 and 2003, U.S. secondary copper-base the historical trends for the United States shown in
scrap collection and processing capacity were Figure 14, in Appendix A of this report. The figure
severely impacted by a number of problems. In shows a graphic illustration of copper consumption
addition to lower scrap prices caused by surplus world from 1927 through 2012 During the U.S. industrial
copper production, higher environmental compliance recovery of the 1988 to 1999 period, refined copper
costs and escalating scrap exports to competing consumption in the United States increased to nearly
nations affected the entire industry. Higher recovery 3 million tons. Copper industrial consumption
costs combined with lower prices from 1998 through increased by about 10.4% between 1994 and 2000. .
2003 to create a cost squeeze that would result in the By 2003, U.S. refined consumption decreased to
closing of all U.S. secondary smelters and associated around 2.3 million tons, recovering modestly to around
electrolytic refineries. Of the four secondary smelting 2.4 million tons in 2004. By 2007, copper
and two electrolytic refining firms operating in 1996, consumption was down again to nearly 2.1 million
none remained after 2001. Fire refining, which tons, and by 2010 was only 1.76 million tons. It is
requires a better grade of scrap, held its own through also worth noting that in 2006, the United States
much of the period, but was also affected by imported record amounts of refined copper, reaching
occasional cutbacks and closings. Plant closings also nearly 1.1 million tons. These record imports were a
occurred in the ingot-making and foundry sectors of continuing sign of a growing and higher U.S. import
the industry. Without a basic domestic secondary- reliance. The U.S. import reliance reached nearly
processing infrastructure, more valuable metals likely 40% in 2006, compared with only 2% in 1993.
will reach the landfill as the most reasonable
remaining choice. Export is always possible for the The decrease in domestic copper consumption was
higher grades of scrap, but the lower-grade copper the result of a struggling U.S. brass and wire mill
by-products, which might be traded domestically, industry. Semi fabricate (tube, sheet, strip, rod etc)
could become less marketable. production suffered as facilities closed. U.S.
production of semi fabricates at brass and tube mills
The significant competition by foreign nations for decreased from 3.9 million tons in 1999 to around 2.9
quality domestic scrap since 1999 negatively million tons in 2007. Two main factors contributed to
impacted U.S. scrap dealers, scrap processors and tubing company demise: increasing use of plastic
users alike. A temporary drop in U.S. scrap exports in pipes for construction applications and increased
2005 probably was partially owing to the threat from a imports of copper and aluminum tubing from China,
short supply petition made to the U.S. Government in Mexico and other countries. Further evidence of the
early 2004 as well as a move by the Chinese industry contraction is illustrated by the fact that an
Government to tighten control on certain metal estimated 16 brass mill plants and facilities closed in
imports. Although the U.S. Government turned down the United States over this period. This contraction
the industry petition for control and monitoring of occurred despite the fact that the United States (2001-
scrap exports, the U.S. scrap availability situation had 2007) was undergoing a tremendous housing boom
improved by year’s end 2004 for a short period. Some and supporting a foreign war, both large consuming
U.S. wire choppers reported significant pickup in activities for copper products. Between 2000 – 2009,
activity and a return to profitability. However, U.S. a total of 695,000 manufacturing jobs were lost from
scrap exports continued at a high pace through 2007 the primary metals and fabricated metal products
and most of 2008, and were more than double the sectors (Bureau of Labor Statistics, 2009).
export rate of 1999. A record of about 1.2 million
tons of copper and copper alloy scrap was estimated While the United States copper industry was
exported from the United States in 2011. shrinking, world refined copper consumption

2
increased to more than 20.5 million tons by 2012 years in the United States and other countries. These
owing to increased growth in other countries. Despite have been applied mainly during times of national
higher secondary (scrap) exports and lower copper emergency and supply shortage. The entire U.S.
consumption, the United States remained a leading secondary copper processing industry was treated as
consumer of copper from copper-based scrap with 9% a critical and strategic industry during these tight
of the world’s total refined copper usage in 2012. In supply periods, such as during WWII and the Vietnam
2012, the United States consumed about 1.793 million War. However, the United States has had no trade
tons of copper from scrap and primary sources, restrictions on copper-base scrap since 1970. All of
including about 735,000 tons from refined and direct the remaining copper in the National Defense
melt scrap. Stockpile was sold in 1993. In April 7, 2004, the U.S.
copper consuming industries filed a short supply
While copper recovered from new, manufacturing petition under the Export Administration Act,
scrap sources has been increasing in the United requesting imposition of monitors and controls on the
States, copper recovered and consumed by industry export of copper-based scrap. The U.S. Government
from old, used product scrap sources has been turned down the petition later in the year.
decreasing. Copper recovered, and consumed by the
U.S. industry from old scrap was as high as 613,000 The U.S. secondary copper processing industry
tons in 1980, but was only 150,000 tons in 2012. currently consists of 5 fire-refiners, 23 ingot makers,
However, if net scrap exports 944,890 tons are 44 primary brass mills, 12 wire-rod mills and about
classified as old scrap and are included in an estimate 500 foundries, chemical plants and other
for all old scrap recovered, the potential amount of manufacturers. Wire rod mills do not consume much
copper in old scrap collected in 2011 was about 1.1 scrap directly. Most of the chemical plants are
million tons (old scrap plus net exports). This much hydrometallurgical plants that have created
higher value implies that the rate of old scrap copper businesses based on using secondary by-products
recovered from the U. S. end-use reservoir has not produced by other metal production and metal
really diminished, as otherwise might be indicated by finishing. Many copper chemicals, such as cupric
reported domestic U.S. scrap consumption data. oxide, copper sulfate and others are produced from
scrap in the United States. Some chemicals are also
World trade (imports) in copper-base scrap nearly produced from the fluid streams of primary copper
tripled between 1989 and 2009, largely in response to refiners. While one chemical plant closed in Texas
the increased industrial growth in the Far East and during 2005, another opened in Arizona, associated
Europe. Asia and Middle Eastern countries received with a primary producer. Two ingot makers have
about 71% of world copper scrap imports in 2010. The closed since 2003, as have an estimated 16 brass
United States continued to be the largest exporter of and tube mills. One wire rod mill closed in 2008.
copper scrap in the world, exporting 22% of the
world’s total copper-base scrap exports in 2011. U.S. The EU-15 as a group of countries is the largest ingot-
exports of scrap were estimated to be in excess of 1.2 producing entity in the world. However, the United
million tons in 2011. The Middle East and Asia region States (30%), followed by Italy, Japan, and Germany,
used an estimated 64% of world copper recovered is the world’s leading ingot-making country. The
from scrap in 2011. (Table 2D) China has become the United States ingot makers provide the domestic
largest copper scrap-consuming nation in the world. foundry and brass mill industries with special alloys for
casting and milling. Ingot-making, in particular, is a
In response to environmental concerns, China very scrap intensive industry, using mostly scrap as its
implemented import controls for scrapped electronics raw material. Even so, the brass mill industry (78% in
and the lower grades of copper scrap in 2002. Even 2010 copper-base scrap consumption) consumes
so, China reduced its import duty on copper scrap in most of the copper-base scrap recycled in the United
2006 to promote the development of the metal States. Some copper tube and wire rod mills have had
recycling industry and to help shortages in the secondary smelters or refineries associated with them
nonferrous metals sector, in general. China, a because of their requirement for high-purity copper.
member of the World Trade Organization (WTO), has Unfortunately, most of these secondary smelting and
been accused by the European scrap processors of refining facilities have closed, owing to a poor
assisting its domestic companies through tax economic environment for processing scrap and, at
subsidies, credit facilities and other protectionist times (as in the late 1990s), the easy availability of
benefits that cause harm to the European scrap metal low-priced primary refined copper.
recycling industry.
In 2011, recycled copper consumed in the United
Trade restraints on scrap, such as import quotas, States was derived 83% from purchased new scrap
export licenses, price controls and other mechanisms generated in the process of manufacture and 17%
have been used many times over the past 30 to 40 from old scrap derived from used products. According

3
to the U.S. Geological Survey, purchased new Spent furnace linings used in pyrometallurgical copper
copper-base scrap yielded about 649,000 tons of and copper alloy processing are also by-products that
contained copper in 2011, 78% of which was sometimes have further value. The type of lining used
consumed at primary brass, tube, and wire rod mills. varies from chrome-magnesite brick to various types
A manufacturer may generate up to 60% scrap in the of ceramic-like materials that are applied like cement.
form of clippings, 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 semi fabricated 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 leach ability 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 23,000 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
2010. 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 (the 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
Though most firms prefer to ship high-grade slags and stemming from application of these laws. For
skimmings (up to 65% copper) to other domestic or example, liability concerns have been enormous
foreign firms for further processing, about 28% of the barriers to brownfield cleanup technologies. A
slag and skimming by-products produced are brownfield is a site, or portion thereof, that has actual
processed in the plant of origin. In addition, pickling or perceived contamination and an active potential for
solutions may also be reprocessed in house to redevelopment or reuse. Because financial institutions
produce copper cathode. A significant proportion of can be liable for cleanup costs when they acquire the
these higher-grade products is exported to Canada or properties through default, they are unwilling to
Mexico as a result of decreased U.S. processing provide loans for development. Problems also
capacity. emanate from the potential responsible party (PRP)
aspects of CERCLA. The potential here is to be
In addition to the copper-bearing ashes and residues, named liable for expensive cleanup solely because
the copper-base secondary industry also produces you may have done business with a firm named as a
significant quantities of zinc oxide as a by-product of Superfund site. This approach to Superfund financing
its metal processing. The USGS estimates that about has caused businesses to think twice about shipping
30% of the world’s zinc is produced from secondary materials to certain firms.
materials, some of which is from the flue dust
collected during copper alloy processing. While some In addition, restrictions on shipping products have
of the production is suitable for direct use as animal increased. Once a product is classified as hazardous
feed and agricultural products, most is sent to zinc and/or is controlled as to market, handling and
smelters and processors for treatment and zinc shipping, costs rise. Higher costs have resulted from
recovery. Only the poorest grades are landfilled. rulings that dictate how much can be stored in one
place or another, what must be classified as
hazardous, who may receive the material, and what

4
procedures must be followed through the entire may be only about 5% and no more than 15% of the
production and marketing process. The permitting total measured consumption.
procedures and handling restrictions have not only
added to the costs of shipping, but have also reduced The domestic copper scrap industry continues to face
the potential for by-product sale to other processors. difficult times in the near future. Not only can a
Further tightening of regulations through continuing difficult economic environment be expected
reclassification of secondary products currently traded as a result of a potentially prolonged recession, but
will result in higher costs and more products sent the underlying negative factors impacting the
directly to the landfill. industry’s competitiveness also will continue. The
sharp drop in copper demand that occurred after
Those firms that can have opted to invest money in September 2008 continued through mid-2009. While
becoming more internalized with increased in-house copper prices and Chinese demand have recovered,
treatment of products. Many have adopted unique domestic copper demand has been slower to respond.
cost-saving devices and policies. Some also are As a result of the lower price since early 2009 and the
instituting formalized, self-policing management slowing industrial economy, scrap supplies have also
systems to improve their processes and products, via been lower. Though lower energy costs may exist
the ISO 9000 and ISO 14000 standards. Some parts temporarily, higher taxes, labor costs, unfair trade
of the government are also taking a harder look at the rules and new environmental costs can be expected
regulations that affect the smooth marketing of to be onerous. The new health care rules are also
products and, in particular, the development of expected to impact ease of doing business. Under
brownfield sites. Nevertheless, the current economic the misguided notion of changing the planet’s climate,
situation continues to look more difficult for some the U.S. government, through either the Clean Air Act,
parts of the secondary copper industry. This segment or new legislation, has the potential to levy onerous
of the economy seems to be laboring under significant regulations on the industry for the control of carbon
stress, caused in part by changing and more stringent and carbon gas emissions. This might be viewed as
government regulations. the “nail” in the coffin. Without a considerable change
in Government attitude toward industry and the
Problems on the horizon include the safe collection economic environment, the outlook will continue to be
and processing of junked electronics equipment and poor. Foreign competition for the scarce scrap
the potential for renewed recycling of radioactive supplies also can be expected to continue.
metal from dismantled U.S. nuclear plants. U.S. scrap
handlers and processors have been adapting rapidly
to handle the increased recycling of electronics scrap.
At the same time, however, adequate provision for
facilities to handle the relatively small amount of
radioactive copper scrap expected from dismantled
nuclear facilities remains a problem to be solved in the
future. More recently, additional charges to be levied
through the carbon capture program associated with
the so-called Global Warming efforts by the U.S.
Government could deal a severe blow to the industry.

How much copper has been recovered for reuse in

the United States over time? Recent calculations
indicate that since 1864, more than 64% of all primary
copper consumed in the United States has been
returned and reused as scrap. Since 1864, based on
reported U.S. data, cumulative primary refined copper
consumed in the United States amounted to 132
million tons by 2011. From this source, a cumulative
46.4 million tons (55.4%) of copper from old end-use
scrap has been returned for consumption by the
industry through 2011. This leaves an estimated 44%
remaining in use or recirculating as new
manufacturing scrap. The latter percentage includes a
very small amount known to have been dissipated
through use as copper chemicals. It is not known how
much may have been irretrievably dispensed with or
thrown away, but it is suspected that this is small and

5
CHAPTER 1: Industry Perspectives from Chile (3.8%), China (28%), Dem. Republic of
Congo (DRC) (20%), Mexico (18%) and Peru (6%).
Mining declined in Australia (-4.6%) and Indonesia (-
35%). Regionally, production rose by 6% in Africa,
4.3% in the Americas, 4.9% in Asia and 3.5% in
Global Industry Perspective Europe, but declined by 4.3% in Oceania.
World Copper Consumption and Production.
Copper ranks third in the world consumption of Over the past several years, the increased Chinese
metals, after iron and aluminum. Refined copper growth in industrial copper was reportedly owing to
consumption is estimated at 20.5 million metric tons stockpiling as well as to new domestic growth, export
for 2012, compared with 16.7 million tons achieved in policies and largely supported by government policy.
2005. According to the International Copper Study By 2009, substantial parts of China’s stimulus
Group (ICSG), for the first ten months of 2012, world package were targeted at infrastructure. Metal
apparent usage of copper grew by 4.2% compared intensive products were also helped by policy
with that in the same period of 2011, principally owing measures. The end result was that China’s demand
to the strong growth in Chinese consumption. Based since 2008 has helped to pick up the “slack” for
on a 40% increase in net imports of refined copper, reduced demand in most of the rest of the world. By
China’s consumption grew by 15.5% in the first ten late 2010, however, a tightening monetary policy in
months, compared with the same 2011 period. There China reportedly tended to dampen excessive
was anecdotal evidence that some of the high stockpiling and other speculative practices.
Chinese import level during early 2012 was supported
by an increase in inventories held in bonded According to the ICSG, China’s refined production
warehouses. Usage in other leading World was 5.79 million tons in 2011 up from 3.8 million tons
consuming regions, the EU, Japan and the United of copper produced in 2008. China maintained a
States, declined by 7.5% and 1.5% or remained position of leading refined copper producer, exceeding
unchanged. World refined production increased by that of Chile (3.1 million tons in 2011)). However,
1.7% during the first ten months of 2012 compared about 35% of China’s refined production is from scrap,
with the same 2011 period. The main contributors whereas all of Chile’s refined production is from
were China (+9%), Japan (+15%) and the Democratic primary sources. China continued to be the leading
Republic of Congo (DRC) (+29%). Refined production world importer of copper concentrates and scrap.
declined by 3% in the United States owing to s series About one-third of China’s domestic scrap
of smelter maintenance shutdowns, and by 67% in the consumption is derived domestically, the rest is
Philippines owing to a fire at its sold smelter. imported.
World mine production increased by 3.9% in 2012

Figure 1. World Copper Inventory Trends

Copper Consum ption Rates and Prices
2500 5
1974 Oil Crisis &
Recession Trade Center 4.5
Recession

2000 4
1982 Recession
3.5
Thousand Metric Tons Copper

Dollars per Pound Copper

1500 3
New Copper
Capacity
2.5

1000 2

Economic Recovery 1.5

and "bust"

500 Economic recovery 1

1979 Oil Crisis
Price
controls
0.5

0 0
65 67 69 71 73 75 77 79 81 83 85 87 89 91 93 95 97 99 01 03 05 07 09 11
19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 20 20 20 20 20 20
Yearend Stocks Avg LME Price 4 Wks Consumption

6
In this report, 2012 production and trade estimates on period. Labor strikes, lower ore grades and other
the data tables were made for the convenience of the production problems also seemed to plague the
interested reader. These current year estimates, for industry. Production and consumption appeared to be
the most part, were based on 8 to 10 months of more in balance by year-end 2006, and inventories
reported data. The previous (2011) year’s estimates decreased slightly through mid- 2008. Except for the
are revised to a provisional status based on published last 4 months of 2008, prices remained mostly above
data now available by the reporting agencies. In $3 per pound, averaging $3.15 for the year. While
recent years, mineral and secondary industries data copper hit its LME price bottom in December 2008, it
from the critical Minerals Information group of the U.S. steadily gained from February 2009 to average $ 2.34
Geological Survey has been severely impacted by a per pound for 2009. Copper prices were significantly
lack of government funding and contraction of higher during the period 2010-2012., exceeding $4
available staff. As a consequence, public data per pound for brief episodes, and averaging about
delivery has continued to suffer. Not many in the $3.42 per pound for 2010 about $4 per pound in 2011
public realize that this organization (previously part of and $3.62 over 2012 (See Table 1).
the Bureau of Mines) is the backbone to U.S. scrap
data collection, which it has been collecting for over Looking back at inventory changes, by January 2009,
100 years. The minerals information community the LME price had retreated to a low of $1.46 per
would otherwise be much more concerned. The pound. Inventories had increased to a world total of
2011 scrap data reported is the data found in the about 1.161 million tons on the exchanges at yearend
USGS 2011 Minerals Yearbook 2008 (ICSG, Oct. 2010).
By October 2012, total inventories held by the
Following several years of soft demand and high exchanges, producers and consumers had increased
inventories on the LME , Comex and SHME, copper to about 1.25 million tons, but was down from 1.34
inventories reached new lows by late 2004 (see million tons in October 2011. To put this in
trends on Figure 1). At the end of 2005, world perspective, this inventory level is less than the 1.7
inventories, according to the ICSG were only 867,000 million tons that is estimated to represent one month’s
tons and about 32% less than that required for one copper consumption for the world. As a result of the
month’s world consumption. Despite efforts by the continued pressure on supplies, the average LME
major copper producers to bring mines back on price for refined copper continued to be in the mid-$3
stream during 2005 and to increase production, range through most of 2012. Prices continued to be
shortages persisted through much of 2006-2008. high through 2011 and 2012, when pressure from
Copper prices exhibited marked increases during this Chinese purchases diminished and the world’s

Figure 2: World Copper Recovery from All Sources1/

And Percent Copper from Scrap, 1976-2012
Percent Scrap Million Metric Tons
50 22

45 20

18
40
PERCENTAGE SCRAP
16
35

14
30
12
25 THE AMERICAS
10
20
8

15
ASIA 6

10
4

5 2
WESTERN EUROPE
0 0

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 08 09 10 11 12
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 20 20 20 20 20

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.

7
economies were affected by continued financial component of world refined copper also decreased
problems. Even so, the average LME copper price from 16% in 1996 to about 12% in 2003. World
was around $3.62 for 2012 (See Table 1). production of refined copper from scrap increased
along with the higher prices that dominated the period
In addition, the China Nonferrous Metals Industry 2004-2008. According to the ICSG, refined copper
Association reported China’s declared inventories at from scrap comprised about 15% of total world
2 million metric tons at the end of 2010 and they had refined copper production 2004 through 2008,
increased significantly by the end of 2011. reaching 18% in 2009 through-2011.

The driving force in China was and is the export A reasonable spread in price also must be present
market, which is responsible for about 40% of the between the current refined copper price and that for
country’s GDP. The drop in global demand because purchased scrap in order for processing to be
of the recession, as well as increased protectionism, profitable. The price spreads between No. 2 scrap and
based not only on duties but more frequently on refined copper are lower or higher in coincidence to
quality standards, certificates, sanitary and ecological the decreasing or increasing refined copper price in
requirements, does not favor an optimistic prognosis recent years. For example, the price spread (between
for future Chinese exports. Exports generate primary COMEX High Grade, first position and Refiners
capital, including wages. Without a strong export buying price for number 2 scrap) in the United States
market to drive China’s economy, the country’s was as high as 31 cents in 1995, but ranged between
economy could fall into a recession. The growth of 11 and 22 cents per pound over the 1996-2004
raw material stocks is explained as a method of period. The price spread for these years was lower
diversifying China’s financial assets from its reliance than the 12-17 cent spread experienced during the
on U.S. bonds and treasury bills. recession years of 1983-1987. The price spreads
increased again between 2004 to 2007 in tandem with
Scrap collection and use tends to be very price the higher copper price. With increasingly stringent
dependent. World copper prices steadily decreased environmental regulations and requirements, the costs
1997 through 2003, as a result of the more than to process scrap at all levels, from low-grade scrap to
adequate world supply of copper (see Table 1). pure metal scrap have escalated. The drastic cost
During this period, copper prices reached low levels squeeze during the poor pricing period (1998-2002)
not seen since the recession years of the early 1980's. prompted U.S. secondary processors to rethink
Since lower prices tend to prompt a decrease in the business methods and in fact, some opted to get out
supply of copper scrap, the use of copper scrap as a of the business. It is encouraging to note that the

Figure 3: World Consumption of Copper from Direct Melt and

Refined Scrap, by Region, 1976-2012

8
Million Metric Tons, Copper Content

6 AMERICA
5

4
MID EAST & ASIA
3

1
EUROPE
0

76 78 80 82 84 86 88 90 92 94 96 98 00 02 04 06 08 10 12
19 19 19 19 19 19 19 19 19 19 19 19 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.

8
estimated average price spreads were 21 cents in (see Table 1). This was also a period of surplus
2004 , more than 31 cents in 2005, 48 cents in 2006, primary copper production. Periods of low scrap
and as high as 34 cents in 2008. recovery, such as those in 1975-1978, 1983-1984,
and again in 2001-2003, coincide with low copper
When the producers price is used in calculating the prices and surplus copper supplies. Scrap supplies
spreads, it adds an extra 4 cents to 5 cents per pound also slowed in late 2008 when copper prices dropped
for shipping and insurance. This is the delivered price. precipitously.
If the COMEX price is used for the comparisons, the
spreads are more narrow. Refer to the scrap and Scrap consumption in Asia has seen a remarkable
refined prices shown in Table 1 for a complete series increase since the early 1980’s. As a group, the
and comparisons. During 2009, variability in scrap Middle East and Asian countries account for about
prices were generally credited to Chinese buying and 64% of world copper recovered from scrap in 2011
lower U.S. scrap generation, and not to increased (see Table 2D). Consumption of copper from scrap in
domestic demand. Asia grew from about 723,000 tons in 1980 to 2.4
million tons in 1995-1996. Following a short industrial
World copper recovered from all forms of scrap contraction in 1997-1998, the region experienced an
(refined and direct melt, Table 2D) decreased slightly 8% drop to about 2 million tons of copper in scrap.
to about 6.7 million tons in 2009, but was up to an However, by 2008, Asia and the Middle East scrap
estimated 8.1 million in 2011. In a word of caution, consumption had recovered to 5 million tons of copper
the actual amount of copper from direct melt scrap per year, largely through the continued insatiable
may be underestimated, since these data (with only a growth of Mainland China. China, with an estimated
few exceptions) are based largely on known (and 47% of world copper recovered from all scrap in 2011,
estimated) semi fabricate production in a particular has become the largest copper scrap-consuming
country. No amount of scrap that might be properly nation in the world.
classified as “home scrap”, or that is lost in the
production process, is added to the direct melt scrap The Chinese Government in its 11th Five-Year Plan
presumed to be part of the end product. The general (2006-2010) was encouraging the greater use of
formula is comprised of total semi fabricate production scrap metals to help alleviate a shortfall in supplies.
less amount of refined copper consumed. The copper The target consumption of secondary copper was
content of direct melt scrap is based on percentages 35% of the total national copper consumption, an
ranging between 75% and 90% of the total, increase of about 14% (Peoples Daily Online, 2007).
dependent upon type of products produced (i.e., brass China’s 12th Five-Year Plan, beginning in 2013 was to
mill or copper rod mill etc). The average copper target an increased electrical grid, calling for more
content is about 80% of total gross weight direct melt scrap copper. China looked to recycle 70 percent of
scrap estimated. The United States reports actual the Nation’s waste streams by 2015 (Resource
numbers for types of scrap consumed, but is unusual Recycling, p. 6, December 2011). China has steadily
among nations reporting scrap data. increased copper in scrap consumed from around
100,000 tons in 1980 to over 3 million tons per year
In 2010, the ICSG published its first edition of Global every year since 2008. Chinese copper scrap
Recyclables Survey. The data covered by this report imports (gross weight) reached 5.6 million tons in
extends through 2008. The survey indicated a 2008 (see Table 4), but has dropped down to about
decrease in global copper scrap use in 2008, owing to 4 .6 million tons per year since 2009. However, in the
a decrease in use of direct melt scrap. The fall off in second half of 2011, scrap import levels at several
direct melt usage in 2008 reflected, in part, falling Chinese ports were curtailed because of an August
overall semis production in the major semis producing 2011 law proposing to treat scrap as waste. More
countries, including the United States, Japan, paperwork is involved and the scrap may be returned
Germany, Italy, Taiwan, the Korea Republic, France to the shipper for violations. Scrap shipments were
and others. (ICSG, 2010 Annual Global Recyclables reportedly backlogged at several Chinese ports.
Survey, 9 p.) Other major copper scrap consuming nations for 2011
in the Middle East and Asian country group (as a
Copper recovered from all scrap, as a percent of total percent of total world scrap) include Japan (61.8%),
world copper produced, has ranged between the low South Korea (3.4%)and India (2%). The Western
of 30% in 2009 to as high as 40% during 1995, as European countries account for 22% and the
shown on Table 2A and in Figure 2. The current rate countries of North and South America accounted for
of recovery (2010 and 2011) is estimated to be about 11% of world copper recovered from all scrap in 2011.
35%. The percentage of scrap used by the world, Germany, Italy, France and the United Kingdom are
relative to primary copper, was noticeably lower after the leading consumers of copper scrap in Western
1996. This trend shows a striking parallel to a Europe. The United States (15% of world total) is the
downward trend in prices between 1996 and 2003 major copper scrap consuming country of the America

9
group shown in Table 2D and Figure 3. The Americas unanimously that the U.S. steel industry had been
(11%) are the third largest copper scrap-consuming materially injured or threatened with injury by imports
region, after Western Europe and Asia. The Oceania of certain tubular (steel pipe) goods from China
and Africa countries are minor scrap consumers. (Recycling Today, 12/30/2009). Some in other
similarly impacted industries viewed this action as
As peak growth years of China’s production of wire, hope for a change in US government attitude.
cable and the copper products seem to have ended.
Challenges for scrap importers remained through Export duties caused Russia’s export of copper scrap
differences in customs between European (70 types to slow to a trickle after 1999. Since that time, Russia
of scrap material listed on manifests) and China (20 restricted the export of raw materials from its territory
types of scrap approved to enter country). Globally e- by maintaining onerous export duties and an
scrap was the fastest growing with 20-50 million tons unpredictable customs service. Such barriers serve to
generated worldwide annually. protect Russia’s manufacturers by artificially inflating
supply and depressing domestic prices for raw
World Trade in Copper Scrap. The United States materials and other inputs. Russia’s exports of copper
(22% of world copper-base scrap exports in 2011) is base scrap increased 3-fold between 1993 and 1998
the largest exporter of copper scrap in the world. U.S. to around 357,000 tons, but since 1999 have dropped
exports of scrap have increased by 132% since 2001. sharply to less than 1,000 tons during 2011. Germany
Access to raw materials such as scrap remains (10%), United Kingdom (9%), France (5.4%), Japan
critically important for all U.S. manufacturing (4.7%), Netherlands (5.5%) and Canada (3%) are
industries. Since 1999, export trade barriers have also major exporters of copper-base scrap, as shown
increased around the world and have been enacted in Table 3 for 2011. Since 1999, exports of copper-
by countries such as China, Russia, Ukraine and based scrap increased significantly from Japan, from
India. These include export bans, export taxes and around 84,000 tons in 1999 to about 425,000 tons for
quotas, export licensing restrictions and currency 2007, but have decreased since then to 288,000 tons
valuations. Many of these trade barriers are in in 2011. World imports of copper-base scrap, as
violation to World Trade Organization agreements, shown in Figure 4, increased 6 fold between the
and all of them adversely impact U.S. manufacturers years 1989-2011 in response to the significant
as well as the general global economy (2008, Wiley industrial growth of the Far East and Europe. The Asia
Rein LLP, Wash. D. C.). In a move contrary to U.S. & Middle East region is the largest recipient for both
government efforts in recent years, the U.S. the United States and World scrap exports. This
International Trade Commission (ITC) voted region received some 73% of total world imports in

Figure 4. Trade in Copper and Copper Alloy Scrap

by World Region, 1989 and 2011

Asia & M.E. 73%

Asia & M.E. 24%
America 15%

America 3%

Europe 61%

1989 Imports 2011 Imports Europe 25%

1.7 million tons 7.7 million tons

America 30%
Asia & M.E. 14%
Asia & M.E. 17% America 28%

2% Row 5%Row

Europe 52%
Europe 50%

1989 Exports 2011 Exports

1.6 million tons 5.6 million tons

Source: International Copper Study Group

10
2011. In 1989, Asia accounted for only a 24% share. In Europe, exports of copper scrap to the Far East
Europe (61%), had a higher share of the world's also increased dramatically between 1999 and 2008.
imports of scrap in 1989. In 2011, as shown in Figure This occurred at a time of lower local scrap availability
4, Europe (West and East Europe) accounted for only in the European Union (EU), creating problems for
25% of global scrap imports. The countries in the European refiners. Some in Europe, as well as in the
Americas (North and South America) have seen their United States, felt that unfair customs regulations, and
share of world scrap imports diminish from 15% lower labor and environmental costs had enabled the
(1989) to around 3% (2011) over this period. Asian countries to pay higher prices for scrap over this
period. The European economy was only slowly
Of all countries, China has had the most significant recovering during 2012. High debt saddled much of
growth in scrap imports over the period 2001 through Western Europe, contributing to a fairly dim outlook
2012, as shown in Table 4. Although Mainland China for 2013. The continuing fiscal problems, specially
apparently suffered a marked collapse in amount of throughout southern Europe was creating a sizable
scrap imported in 1996 and 1997 owing to import drag over much of the economy. Demand for
restrictions, copper base scrap imports were again nonferrous metals was expected to be somewhat
higher by 1998. By 2001, China’s imports of copper- muted through the first half of 2013, though pricing
based scrap was 4-times that of 1996. By 2007, may be finding a floor (Recycling Today Global, Jan
Chinese imports were 67% higher than that of 2001. 2013)
South Korea, Taiwan, Hong Kong, Japan and India
also have been significant importers of copper base Owing to decreased manufacturing levels and other
scrap in recent years. problems, scrap exports from Europe dropped off
during 2009. The brass and copper industry in Italy
Looking back, by early 2001, the availability of copper was reported as operating at 60% of capacity
scrap was reported as especially tight in the United (Recycling Today, Dec. 2009). Italy, normally a large
States, owing to low prices and the higher exports to importer of copper scrap, had decreased imports to
the Far East. Birch/cliff and berry/candy grades were around 148,00 tons in 2011. (see Table 4). By
in particular demand. This difficult situation coincided September 2010, half the brass industry in Italy had
with the closure of the last secondary copper smelter been closed and half were sitting idly by (Recycling
in the United States in 2001. Since that time, China Today, Sept/Oct 2010). Some recovery was indicated
has emerged as the major outlet for U. S. exports of by the increased Italian scrap imports during 2010 and
No. 2 scrap and mixed grades of alloyed scrap, in 2011 (see Table 4).
particular. Supplies of scrap in 2009 and 2010
continued to be very tight in the United States as a In recent years, the United States has increased its
result of lower prices in 2009 and a drop-off in domestic collection and processing of electronic
manufacturing-based new return scrap.. With the scrap, but U.S. export of low-grade copper scrap
precipitous drop in copper prices in 2008-2009, a derived from electronic products such as computers
cutback of copper demand from China and equally remained an issue of concern. A report issued in
abrupt cancellation of several contracts, U.S. copper 2011 by the Institute of Scrap Recycling Industries
scrap exports slowed to a trickle through early 2009. (ISRI) indicated, from a survey of 182 U.S.
Supplies to U.S. metal traders essentially dried up organizations, that most end-of-life electronics were
while the prices were trying to stabilize. In late 2008 now being processed in the United States and not
and early 2009, some dealers were stuck suddenly dumped overseas.
with supplies for which they had paid much higher
prices than the current buying market. By yearend Even though China was tightening its rules for
2009, however, owing to higher prices, dealers importing electronics scrap, other poor countries may
reported that orders had picked up, but there still still be willing to accept these materials. According to
wasn’t much excess material available, but China was some reports (Recycling Today, Feb. 2002), Pakistan
again active in the market.. Along with a shortage of had become a bigger market for electronic scrap and
scrap generation during 2009, container availability used computers. China reportedly applied import
also was a problem for some overseas shippers. By restrictions on electronic scrap and in May 2002
the spring of 2010, higher prices prompted more scrap instituted a substantial tariff on class 7 scrap. This
to come out of the system. Copper rose to about class includes lower grades of copper scrap such as
$3.50 in April. Domestic brass and bronze ingot unprocessed wire and die cast alloyed parts. The tariff
makers were buying on a more limited basis from may have also been enacted to force the domestic
regular suppliers. Even so, mid-2010 saw another smelting industry to use higher grades of scrap as a
slowdown as Europe entered its slow season and pollution reduction measure. China continued to
margins were being squeezed with difficult pricing. tighten regulations and began in November 2004 to
ban all used television sets and other electronic scrap
imports in a bid to clean up its environment.

11
China reportedly reduced the import duty on copper In 2010, China published Notice 32, which required
scrap in 2006 and 2007 to promote growth in the separate packaging of different materials. In addition,
metal recycling industry and assist the nonferrous China’s General Administration of Quality Supervision,
metal sector in its need for raw materials. China Inspection and Quarantine (AQSIQ) registration
reduced the import tariff for copper scrap from 1.5% to process was defined for overseas suppliers on July 1,
0% in mid-July 2007 (ISRI Friday Report, July 20, 2010. Certification to ISO 9001, Recycling Industry
2007). In late 2007, China announced that it would Operating Standard (RIOS) or an equivalent quality
remove import duties on refined copper. The 3% assurance standard would be required for first time
import tax for refined copper was cut on Jan. 1, 2008 applicants for an AQSIQ license. (Recycling Today
(12/28/07, www.recycleinme.com). In mid-November 7/30/2010).
2005, China also signed the first East Asian trade
agreement with Chile (a major source of primary Export controls on scrap (such as those imposed in
copper) as an important bilateral trading partner. China, Russia and Ukraine) have been commonly
applied in the world during periods of scarce supply.
To maintain adequate supply for the home market, the Historically, copper base scrap has been a highly
Chinese Government applied strict controls on the prized raw material, especially in those nations with
export of copper-based products. In November 2006, scarce natural raw material sources for copper.
the export tax rebate on copper products was cut to European scrap export controls during the 1980’s
5% from 13% and the export tariff on copper were seen as affecting the U.S. copper industry
concentrates increased to 10%. Meanwhile, export unfairly. As a result, the U.S. Copper and Brass
tariffs on copper scrap, blister copper and electrolytic Fabricators Council (CBFC), representing domestic
(refined) copper were also raised. The Chinese brass mills submitted a 301 petition concerning the
Government levied an export tax on nonferrous scrap trade of copper and zinc scrap to the U.S. Trade
at 10% from June 1, 2007 (Recycling Today, May, Representative on Nov. 14, 1988. The application was
2007). In September 2007, a huge back up of not successful in developing U.S. controls. Domestic
containers filled with scrap was reported, caused by a semifabricators asserted that European (EEC) and
crackdown on importers trying to avoid complying with Brazilian brass mills had been able to maintain
the new duties for scrap. Two months previously, materials cost and product price advantages since the
Chinese customs officers launched a major offensive middle 1970’s, largely through export controls on the
against importers, who had been trying to avoid flow of copper and zinc scrap. However, in 1992, the
complying with new duties. There also had been a EC terminated the export controls on copper and
widespread practice among many Chinese importers copper alloy scrap. Several Asian nations and Russia
of mixing lower content scrap with higher purity have maintained scrap market controls in recent
material to avoid paying higher taxes. Duties are years. The Bureau of International Recycling (BIR), a
applied to the copper content, so a reduced copper European recycling organization, recently assisted
content means lower duty. Another problem area is Romanian companies in opposing a Romanian
“mixed” loads of scrap where the high value copper is governmental decree to impose 20% to 30% export
loaded in front of the container and lower grade scrap taxes on nonferrous and ferrous scrap.
is loaded in back.
In April 7, 2004, the CBFC and Non-Ferrous Founders
In mid-summer, 2009, a slowdown in customs Society filed a short supply petition under the Export
clearance in Guangzhou, China was reported as Administration Act, requesting imposition of monitors
having a big effect on domestic importers of copper and controls on the export of copper-based scrap.
scrap. A large number of containers were stranded at ISRI and its members were opposed to the petition as
the ports. The number of containers were reported as they did not want exports restricted. The Commerce
exceeding 2,000 at each port (Recycling Today, Aug. Department issued its decision in August 2004 citing
2009). The government was introducing new no need for controls or monitoring of copper-based
procedures to standardize and improve imports of scrap exports. See Appendix A for a more complete
metal scrap. Inspection was intensified to prevent discussion.
violations of price deception, lower bidding and
omission of proper reporting. In October, 2010, China The voluminous paperwork requirement the Chinese
for the first time in 3 years raised interest rates, government implemented for the importation of scrap
reducing loan volume by an estimated 22%. China also was viewed as an impediment in early 2004.
felt its strong economy was becoming inflationary. Some scrap recyclers and brokers labored to comply
This caused a slight correction in metal prices, but the with export regulations being put in place by the
upward trend was still intact and continued through Chinese Government’s Administration of Quality
much of 2011. Supervision Inspection and Quarantine (ASQIQ)
(Recycling Today, August 2004). The significant load
of paperwork required had an initial deadline set at

12
July 1, 2004 in order to be registered or permitted to been imported as copper scrap, since these have
ship scrap to China. Not only the information been prohibited since Aug. 15, 2002.
requirement was tedious, but some information such
as floor plans and other operational details of the Ukraine’s parliament gave approval to a bill in late
exporting company, required to qualify for the CCC 2006 that would lift the ban on exports of scrap
mark system, was objectionable. The suspicion nonferrous metals. An export duty of 30 Euros per
existed that the Chinese importers were determined to metric ton would apply the first year the bill is in effect
help themselves to efficient production facility know - and would be gradually reduced to 15 Euros per
how through this information. metric ton over the next 5 years. The duties would
start when Ukraine joined the World Trade
Another problem with copper scrap exports to China Organization. (Recycling Today, 11/30/06). Export
revolved around China’s handling of its VAT (Value- taxes are not the only trade barrier that Ukraine
added Tax). The VAT tax on copper waste and scrap maintains. Ukraine does not allow the export of scrap
was 17% in 1999 (www.chinavista.com). The same metal products unless exporters are properly
tax applied to refined copper imports. Chinese copper registered with the Ministry of Economy and are
scrap importers and Chinese customs officials were issued an export license. Export registration fees also
accused of manipulating the VAT to the detriment of obstruct trade in scrap metals. Until recently, the fee
U.S. industries. Chinese importers received a rebate for export licenses for ferrous and non-ferrous scrap
on VAT and then further manipulated import was five times higher than the ordinary customs
documents to gain greater VAT refunds. These clearance fee of 0.1 percent of the value of the export
actions caused global copper scrap prices to rise contract. Despite Ukraine’s pledge to reduce its high
because Chinese importers could pay more for scrap, export taxes in 2006, political divisions leading up to
but still make a profit. U.S. manufacturers that use the 2010 presidential election, coupled with the
scrap were faced with higher prices for raw materials, substantial influence of industry leaders, have slowed
thus increasing their production costs. Finished progress towards trade liberalization and deregulation.
products from China were subsequently undersold in In the face of its commitments to eliminate or reduce
U.S. markets (US Info.State.Gov. 10/7/2003). export and import bans and tariffs across a wide
variety of industries, and just days after Ukraine
In December, 2008 (Recycling Today, Dec.2008), became a working member of the WTO, the Ukrainian
China’s Nonferrous Metal Industry Association parliament passed a major bill containing export and
(CNMIA) announced that the government was import duties that were in direct violation of WTO
considering canceling the 17% VAT tax on scrap agreements (Wiley Rein, 2008).
imports. The CNMIA hoped the move would help
companies cut costs as the economy slowed. In late 2009, the Bureau of International Recycling
(BIR) was reported (Recycling Today, Aug. 2009) as
Pegging the yuan to the dollar was also reported as a pressing India to make changes to its requirements for
deliberate strategy to support Chinese industry and the import of recyclables. Imports were being
boost exports. China’s undervalued currency was impeded by the requirement of pre-shipment
acting as an additional trade barrier to U.S. exports inspection certificates. The new Indian rules restricted
and an unfair subsidy for all Chinese exports imports to end users and thereby excluded traders.
(Congressional-Executive Commission on China, Sept This was a major issue for trading companies and
24, 2003). their business associates, who were seeking
amended rules.
Some observers have used problems in Chinese
trade regulations to explain the tremendous World Production and Trade in Copper Alloy Ingot.
differences between reported world statistics for While copper and copper alloy ingot production and
copper scrap imports and exports. (See Tables 3 and trade are not large in volume compared with other
4 in this report for differences.) Among importing copper products; they form the foundation blocks for
countries, the import statistics for China seem to be important specialty metal fabrication industries. Many
the most suspect. Copper scrap imports are over nonferrous foundries, brass mills, steel mills and other
reported because some other industrial recycle parts of the world's manufacturing industry are
material has been claimed at customs as copper or dependent on the special alloys produced by these
copper alloy scrap. Some believe this may be the essential-processing plants. Because the ingot
result of the lower copper scrap import duty relative to makers and associated foundries of the world are
other industrial wastes. Some traders may be trying to heavily reliant on scrap, especially old scrap from
avoid the higher import duty by importing non-copper returned manufactured and used products, it is
industrial waste as copper scrap. Imports of scrapped important to put this industry in world perspective.
electrical domestic and office goods also may have

13
The United States is a world leading producer of from about 23,000 tons per year in 1999 to around
copper and copper alloy ingots and foundry products 4,000 tons per year in 2003, but increased to around
from scrap (see Tables 5A, B and C and Table 10). 10,000 tons in 2006, and 12,100 tons in 2010. Ingot
The United States produced 254,000 tons (23%) of imports have decreased generally in every region of
world nonferrous foundry products in 2002 , but only the world with exception of the Middle East and Asia,
194,000 tons in 2010, about 12% of world total. In which has tripled the amount of alloy ingot imports
2009, Italy (4.2%), Japan 5.3%) and Germany (5.4%) since 1999. China, in particular, increased ingot
are also significant producers of nonferrous foundry imports from 28,000 tons in 2001 to 39,800 tons in
products. China (42%) has increased foundry 2010 (See Table 5B).
production significantly since 1999, producing more
than 600,000 tons per year since 2008.

The United States produced 27% of the total world Domestic Industry Perspectives
ingot production of 438,000 tons in 2008 (See Table
5). Nearly 80% (349,000tons) of the world’s alloy Domestic uses for Copper. About 75% of the copper
ingot production, of around 438,000 tons per year in consumed in the United States is for electrical and
2008, was exported (see Table 5C) The ICSG electronic uses, finding widespread application in
Copper Bulletin reported world ingot imports at most end use sectors of the economy. According to
248,000 tons and exports were 310,000 tons in 2010. the Copper Development Association (CDA),4,977
During 2011, China (15%), Germany (13%), Italy million pounds (1.195 million metric tons) of copper
(6%), Taiwan (4.3%), Canada (1.8%), and France and copper alloy mill products were shipped for
(3.4%) were the largest importers of ingot. Since domestic 2011 end-use markets. The products were
1999, China has decreased its imports of ingots from distributed in sectors as follows (electrical is
around 63,600 tons in 2005 to around 39,600 tons in distributed through all end-use markets): Building
2010.. Construction (44%), Electrical and Electronic Products
(20.4%) Industrial Machinery and Equipment (7.4%),
The leading exporters of ingot in 2010 were the United Transportation Equipment (16.4%) and Consumer and
States (35,700 tons), Japan (21,800 tons), Germany General Products (11.8%). In 2011, copper wire mill
(12,300 tons), the United Kingdom (16,900 tons), production of 2,721 million pounds was much below
South Korea (21,200 tons), and Spain (16,000 tons). the high point of 4,580 million pounds for 1999.
Over the past 8 years, U.S. ingot exports were Though smaller in total tonnage than the electrical and
between 29,000 tons and 40,000 tons, reaching a electronics uses of copper, the copper powder and
peak in 2007. U.S. ingot imports decreased markedly chemical industries also provide important products.

Figure 5. U. S. Total Copper Consumption 1/

Including All Scrap, 1966 to 2012

Million Tons, Copper Percent Scrap in Consumption

5 60

50
4

40
3

30

2
20

1
10

0 0
6 8 0 2 4 6 8 0 2 4 6 8 0 2 4 6 8 0 2 4 6 8 0 2
1 96 1 96 1 97 1 97 1 97 1 97 1 97 1 98 1 98 1 98 1 98 1 98 1 99 1 99 1 99 1 99 1 99 2 00 2 00 2 00 2 00 2 00 2 01 2 01

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.

14
Copper and copper alloy powders are used for brake refined copper consumption for 2012 was estimated to
linings and bands, bushings, instruments, and filters in be 1.79 million tons. (See Table 6)
the automotive and aerospace industries, for electrical
and electronic applications, for anti-fouling paints and Recycled copper used to make semi fabricated
coatings, and for various chemical and medical products may be derived from (1) scrap that is first
purposes. Copper chemicals, principally copper refined before use (refined scrap), or (2) from copper
sulfate and the cupric and cuprous oxides, are widely and copper alloy scrap that can be directly melted at
used as algaecides, fungicides, wood preservatives, the time of use (direct melt scrap). Total refined
copper plating, pigments, electronic applications and copper, from both primary and secondary sources,
numerous special applications. See Tables 10, 10A consumed by the U.S. industrial sector in 2011 was a
and 10B in this report for production and trade in about 1.76 million tons, according to the U.S.
some of these products. Geological Survey (see Table 6), and considerably
lower than the high point of 3 million tons in 2000. Of
U.S. Consumption of Copper. In the United States, the total refined copper consumed in 2010 only
copper derived from both primary (mined) and 143,000 tons (or 2%) was derived from scrap
secondary (recycled) sources is consumed at processed at a refinery (see Table 7). This is down
industrial production plants. U.S. industry import considerably from 480,000 tons (25% of refined
reliance for copper in the last 14 years has increased consumption) of copper from refined scrap in 1989. In
from less than 1% of domestic consumption in 1991 to addition, the United States industrial sector consumed
over 48%, and 32% in 2003 and 2008, respectively. about 705,000 tons of copper in 2011 derived from
In 2006, a record level of refined copper, around 1.1 direct melt, copper-based scrap (See Table 2C). Total
million tons, was imported into the United States. In copper from scrap (refined plus direct melt copper
excess of 600,000 tons of refined copper has been base scrap and from other than copper-base scrap)
imported by the United States each year 2008- 2010. amounted to about 742,000 tons in 2010. The range
This compares with only 343,000 tons of refined in annual average copper content for direct melt
imports as recently as 1993. Copper derived from copper-based scrap in the United States has been
domestic mines and as well as from domestic scrap 83% to 85% of the gross weight over the past 10
sources has steadily decreased in recent years as years, according to an analysis of data provided by
imports of refined copper have increased. As copper the U.S. Geological Survey.
consumption at U.S. plants dropped further in 2008,
however, the rate of refined imports also declined. US Traditionally, scrap used in refining and smelting has
refined imports for 2011 were only 297,300 tons. U.S. been made up mostly of “old” scrap, while the

Figure 6. Trends in U.S. Net Exports and Consumption

of Copper in Scrap 1/, 1981 - 2012
1600

1400

1200

1000

800

600

400

200

0
81 982 983 984 985 986 987 988 989 990 991 992 993 994 995 996 997 998 999 000 001 002 003 004 005 006 007 008 009 010 011 012
19 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 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.

15
purchased direct melt scrap used by brass mills is Table 6) copper from scrap has declined from 49%
mostly “new”, customer-returned scrap. The rate of since the early 1980’s to around 30% in 2007. Despite
recovery for “old” scrap copper in the United States is the robust U.S economy over much of the period
related to the variability in the copper price, the 1994-2007, domestic use of copper from old scrap
domestic industry demand for this type of raw and refined from scrap, in particular, experienced a
material, competition from exporters, and the significant decline (See Tables 6 and 7). For
availability of primary copper. The small amount of example, copper from old scrap recovery was as high
U.S. secondary refined copper in 2009 was 55% as 613,000 tons in 1980, but was only about 143,000
derived from old scrap sources and 45% from new tons in 2010. Exacerbating the decline in collection,
scrap sources, according to the U.S. Geological processing and consumption of old and low-grade
survey (2009 MYB, Table 7). The amount of scrap in the United States has been the closure of
secondary copper in U.S. refinery production in 2009 essential U.S. smelting and refining plant capacity. All
was only 46,400 tons out of a total 1.08 million tons U.S. copper scrap smelting plants, most scrap refining
refined copper, and only 18,000 tons (revised down) plants and some ingot makers have closed owing to
of a total 1.054 tons produced in 2010 This was down the higher costs associated with tight environmental
considerably from around 480,000 tons of refined regulations, increased worker safety standards, and
copper derived from scrap in 1989. The significant the competitive pressures from increased export of
decrease observed since 2000 was the result of the scrap.
gradual and complete closure of all of the secondary
smelters in the United States. Refer also to Figure 8 Scrap is a necessary raw material in the U.S.
for complete statistical details on smelter capacity manufacturing cycle. Not only does the U.S. industry
changes over this period. generate many tons of copper-base scrap, but it also
needs and uses many thousands of tons each year
Ingot making also uses large quantities of copper during the process of new manufacture. Customer-
from "old" scrap (84% derived from old scrap in 2009). returned new scrap tends to be recirculated to the
Copper from old scrap only made up 16.4% of total plant of domestic origin. In 2009, about 98% of
copper recovered from copper-base scrap in 2009. copper-based scrap consumed at brass and wire rod
(USGS, 2009MYB, Table 7). Some copper tube mills mills was new scrap, according to the U.S. Geological
may use a higher proportion of old scrap when Survey (2009 MYB Table 11). The purchased scrap
purchased from dealers as good clean, No. 1 copper market gradually increased in the United States
scrap. It is many times impossible for a mill to through 1997, as shown in Table 6 and in Figure 6.
determine whether the scrap is “old” or “new” in its This increase has been presumed to reflect the
origin after it has been chopped and processed by an steadily increasing industrial base, from which more
intermediary. customer return scrap is generated. It was also the
result of the gradual decrease in processing capacity
U.S. scrap statistics shown in Table 6, represent for old scrap. Since 1997, however, total scrap use
consumption, or copper scrap usage, as reported at has declined, coincidental to the significant increase in
industrial plants, and thus, do not reflect the total U.S. scrap exports (Table 3 and Table 8). Lower
amount of material collected at scrap dealers and copper prices (see Table 1), associated with an
traders. An increasing amount of U.S. scrap collected increase in primary copper supplies until 2003, also
has been exported in recent years. Using an contributed to decreased use of scrap Though higher
assumption that most internationally-traded copper copper prices generally have been the case since
scrap may be derived from used materials, the 2004, significant foreign competition for scarce
addition of U.S. scrap exports to old scrap reported as domestic supplies continued to impact copper
consumed by the industry will provide an estimate of availability for domestic firms through 2010. A
total old scrap recovered in a particular year. This also general decline in copper-base manufacturing plants
assumes, of course, that most new scrap is returned has also impacted domestic return scrap from this
to the domestic mill of material origin and is not also source since 2001.
sold abroad.
Even while the brass and wire mill sectors of the U.S.
Old scrap recycling and its contribution to U.S. total secondary-based industry were expanding capacity,
copper derived from scrap has fallen from 43% in mill consumption of scrap copper relative to primary
1992 to 18% in 2010 (see Table 6). U.S. recovery and copper was decreasing. Until 1982, copper from all
consumption of “old” scrap was highest during WWII, scrap sources had grown each year in the United
the 1950’s and 1960’s, which were years of high States, as a percent of total copper consumed,
copper demand and good prices. Old scrap recovery varying between 7% (in 1906) to 50% (in 1950).
was also high during the Great Depression years, However, from a peak of around 49% in the early
when mine production was severely curtailed. As a 1980’s, the contribution of copper from scrap to
percent of total copper consumed, (see Figure 5 and domestic copper usage gradually has been

16
decreasing to around 30% in 2007 (see Table 6). time. Lower scrap imports and exports in 1996
Copper prices have escalated since 2003, but a through 1999, were the result of the worldwide
coincidental increase in US industrial scrap depressed copper prices, the strong U.S. dollar and a
consumption did not accompany the higher prices. temporary setback in Chinese imports during the early
Instead, U.S. scrap exports steadily increased over part of this period. The lower scrap price and stronger
the period. dollar also combined to make U.S. scrap scarce for
domestic buyers, as well as expensive for foreign
Copper consumption from scrap, as shown on Table buyers over that short (1996-1999) period of time.
6, does not include the significant amount of run-a- Since 1999, however, foreign buyers (principally
round or home scrap that is generated at every plant. China) have managed to outstrip local mills in
Between 15% and 40% of raw material consumed competition for scarce purchased scrap.
remains in the production cycle of brass and wire mills
and is recycled again and again. To include this U. S. copper and copper alloy scrap exports set
material in consumption statistics each year, however, another record in 2011 reported by the USITC (data
would be to double count the material each time it webb, Nov 2012)at 1.239 million tons (see Table 8A).
passed through the production process and was Since 2005, U.S. trade statistics have tracked the type
scrapped. Yet, this material is available and forms an of scrap in its export statistics, as shown on Table 8A.
essential part of the semis production cycle. While unalloyed scrap exports remained around
Unfortunately, few statistics are available to quantify 350,000 tons per year until 2011, alloyed and mixed
run-a-round material. scrap exports have escalated from around 300,000
tons in 2005 to 738,730 tons in 2010. The bulk (80%)
U.S. Trade in copper and copper alloy scrap. of this mixed copper and copper alloy scrap has been
Copper and copper alloy scrap of all types has destined for China (USGS, Dec 2008 MIS, Table 17).
significant intrinsic value for the manufacturing In 2012, unalloyed scrap exports reached an
industries of both the United States and the World. estimated 484,000 tons.
Copper base scrap, including lower-graded copper
materials with by-product metal value, are all In lieu of scrap, primary copper at bargain prices
commodity-like materials that are traded (bought and between 1998 and 2003 provided a ready substitute in
sold) and used just like other raw materials. As a the United States for those who could utilize it.
consequence, recycled materials form a significant However, owing to the types of furnaces used, size of
part of the U.S. copper exports and imports. This has charge needed, and chemical requirements for certain
been particularly significant in recent years since the alloys, this was not possible for all secondary metal
manufacturing bases of the Asian countries have users, and the market became difficult for these
been growing and demanding more raw materials. industries. Those mills and ingot makers that were
The domestic market for scrap is still as large as dependent upon direct melt alloy scrap were highly
exports though exports have been growing at a fast affected by the increased U.S. exports.
rate. U.S. industry consumption of scrap has
decreased from around 1.77 million tons in 1997 to The trend in U.S. net scrap exports appears as a
about 930,000 tons in 2010(see Table 17). Net mirror image to the trend of copper recovered from
exports of copper scrap for 2011 were slightly higher refined scrap, as shown in Figure 6. When refining
at 944,890 tons. from scrap (largely “old” scrap) is high, net exports
(exports less imports) are lower. Lower exports and
The United States is a significant exporter of copper higher imports of scrap in the early 1980’s were in part
and copper alloy scrap as shown on Tables 3 and 8, owing to the stronger dollar of the period.
and has been the world’s largest exporter of copper-
based scrap since 1999. U.S. net exports of scrap in Trade in low-grade, copper-containing ash and
2011 were estimated at 944,890 tons, up from a net residues has been recorded by the Bureau of the
export of around 62,700 tons in 1993, and 140,000 in Census under HTS 262030 since 1989, when the
1997. The most significant U.S. scrap export harmonized code was instituted in the United States.
destinations are in Western Europe and Asia. Prior to this nomenclature, the TSUS standards and
Although the amounts have been declining since nomenclatures were used. For exports, the TSUS
1997, the United States also imports around 100,000 number is 6030010 and for imports, it is TSUS
tons per year of scrap. The most important U.S. 6035040. Exports of "ashes and residues containing
import sources of copper and copper alloy scrap in mainly copper" are reported in gross weight of
2008 continued to be Canada (40%) and Mexico material. The import data are in copper content, but it
(35%). Scrap exports generally have been increasing can be extrapolated to gross weight for comparison
since the early 1970’s. Exports suddenly doubled with the USGS reports for consumption of low-copper
between 1999 and 2000 (see Table 8), and have ashes and residues. Although the material may
remained well over 500,000 tons annually since that contain up to 65% copper, an average copper content

17
of 35% was used in estimating the gross weight for as to cut off major sources for copper around the
exports and imports on Table 9. world at times, it is highly possible that export controls
and the pressure for increased use of secondary
The major trading partners receiving ashes, residues copper can occur again. All of the remaining copper in
and slag from the United States for further processing the National Defense Stockpile was sold in 1993.
are Belgium, Canada, Germany, Mexico, the United
Kingdom and, more recently, China. Major import
sources are the copper producers of Botswana, Chile,
Mexico, Canada and Australia. Copper ashes and Products and by-products from Scrap
residues exports increased from the early 1980's to
reach 28,110 tons in 1995, but then decreased to as Wrought copper and copper alloys. The making of
low as 2,950 tons in 2002. Since 2004, copper ash brass and bronze wrought metal alloys by brass mills
and residue exports again began to increase and, in accounts for the largest share of copper recovery from
2007, and 2011 were 62,150 tons and 38,300 tons, scrap. Wrought copper and copper alloys are
respectively. Imports of copper-containing ashes and produced from purchased scrap, home scrap, refined
residues have been decreasing; from 5,400 tons of copper, and other metal alloying additives. These
copper content in 1988 to less than 700 tons in 2002 alloys are fabricated into products such as sheets,
(see Table 9.). Imports of ashes and residues tubes, rods and pipes. Wire rod mills produce
increased slightly since 2003, reaching 8,700 tons in continuous cast, pure copper rod for making wire that
2007, but were lower at less than 1,000 tons for is drawn down to various types of coated and
2009 through 2011 (Table 9). uncoated wire. Because of the stringent
requirements for making copper wire, wire rod mills
Because many of these materials are associated with use mostly refined copper in making rod. The small
the brass and bronze making process, trade in zinc amount of scrap that is used by wire rod mills must
dross, skimmings, ashes and residues are also shown first be refined. Only one wire rod mill in the United
in Table 9. As measured in zinc content of zinc ash States has a continuous system for fire refining,
and residues (HTS 26201960), exports reached a melting and rod casting from scrap. This mill uses the
peak in 1992, but declined through 1999 to 4,500 company's own customer-returned scrap from its
tons. Exports of zinc ash and residues increased wholly-owned wire mills in the fire-refining plant.
significantly since that time to reach 25,000 tons in
2002, and 13,200 tons in 2004. Zinc residues exports For 2011, the combined semi fabricate production of
were 9.350 tons in 2010 and 15, 460 tons in 2011, brass and wire mills amounted to 2.2 million tons of
according to ITC reports. Zinc ash and residues copper and copper alloy products. (Table 10). This
imports steadily increased to around 24,300 tons, as was somewhat lower compared with 3.4 million tons
measured in contained zinc through 1998, but then of semi fabricate products produced in 2004 (Table
decreased to a range of between 14,000 and 17,000 10), and considerably lower than the peak of 3.9
tons until 2005. Zinc ash and dross imports were million tons reached in 1999-2000. The current lower
again higher at 33,750 tons in 2006 but have been production rate is the result of continued U.S.
lower for the past several years at less than 1,000 industrial retraction that has been experienced since
tons annually (See Table 9) 2000. About 16 brass and tube mills have closed in
the United States since 2000 (see Table 13A). Two
U.S. Export Controls on Scrap. During periods of main factors contributed to tubing company demise:
high military activity and/or difficult economic (1)increasing use of plastic pipes for construction
conditions, copper and copper-base scrap has been in applications and (2) increased imports of copper and
such tight demand and scarce supply that U.S. export aluminum tubing from China, Canada, Mexico and
controls and other restrictions have been placed on its other countries. More recently, a large wire rod mill
use. Tight supply periods occurred in the 1960's and closed in Illinois.
early 1970's, occasioned not only by requirements of
the Vietnam War, but also by the effects of long U.S. copper consumption statistics, as shown in Table
copper mine labor strikes during the late 1960’s. To 6, are reported from brass and wire mill activity. These
compensate for the severe shortages, more than 1 statistics do not represent the entire U.S. population’s
million tons of copper from the National Defense consumption of copper in finished products. The
Stockpile were released. In addition, during the early statistics for the domestic population would include
1970’s, price controls were briefly implemented. A copper contained in finished and semi fabricate
review of the historical events surrounding the use of imported goods. To determine a complete U.S.
export and price controls relative to the copper market societal copper consumption estimate, copper in
and the need for copper scrap may be found in imported finished goods also should be considered,
Appendix A. Given the propensity for military efforts such as copper in imported cars, refrigerators and
to use large amounts of copper and its alloys, as well other goods. These statistics are difficult to estimate,

18
and is beyond the scope of this paper. Judging by the size to suit foundry furnaces. Production trends for
volumes of products scrapped, however, it is several broad ingot groups are shown on Table 10 .
suspected that the U.S. society remains the largest The most important of these are the red brass,
consumer of copper in the world, regardless of where bronze, and yellow brass groups. Figure 7 clearly
the product originated or how it was used. shows the gradual decline in U.S. ingot production
since the middle 1980's with another sharp drop since
Brass and Bronze Ingots. Ingot making was a 2000. The leaded and semi-leaded red brass and the
critical U.S. industry during World War II, comprising a tin bronze categories of ingot seem to show the most
basic support for the essential brass mill and foundry volume decrease since the late 1980’s. A decrease in
production needed for the war effort. This was so hardeners and master alloys also has occurred since
much the case, the Defense Production Act required 2000. The general ranges in ingot compositions are
that, among all other Government copper surveys, shown on Table 11. There are actually hundreds of
only the ingot maker, foundry and brass mill data ingot metal compositions designed for special tasks.
surveys were mandatory under penalty of law. Special The groups shown in Table 10 are very general.
alloys and the special castings, fittings and parts
made for military uses were dependent upon domestic Individual grades of copper and copper alloys have
production from ingot makers and foundries. been designated in the past by a three-digit number
series developed by the industry. More recently,
Ingot production ranged from 300,000 tons to 380,000 however, this series has been incorporated into the
tons of ingot in the 1960’s and 1970’s. However, Unified Numbering System (UNS) for metals and
ingot production has been less than 200,000 tons in materials developed by the American Society for
the United States since the 1980’s. According to the Testing and Materials (ASTM) and the Society of
U.S. Geological Survey, ingot production (including Automotive Engineers (SAE). This system designates
master alloys) in the United States was 125,000 tons each alloy by 5 digits preceded by the letter C. The
(see Table 10) in 2008, but was down to 108,000 tons UNS system is administered by the Copper
in 2011. U.S. ingot exports have increased Development Association Inc.(CDA). There are about
significantly in recent years to around 28,000 tons in 370 types of copper and copper alloys divided into the
2008 and 35,700 tons in 2011 (see Table 5C). U.S. broad categories of wrought and cast metals. Within
ingot imports also increased to around 9,000 tons in these two categories, the metals are further
2008, and reached an estimated 15,400 tons in 2012. subdivided into classes as follows:

Ingot makers produce a wide range of cast copper Coppers: Metals containing at least 99.3% copper.
alloys for the nonferrous foundries. Ingots weigh about There are 44 numbered coppers, including oxygen-
30 pounds each when cast, being of a small enough free, tough-pitch, and deoxidized varieties.

Figure 7: U.S. Copper Alloy Ingot Production

By Ingot Group, 1984-2011
Thousand Metric Tons, Gross Weight
250

200

150

100

50

84 985 986 987 988 989 990 991 992 993 994 995 996 997 998 999 000 001 002 003 004 005 006 007 008 009 010 011
19 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2

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

19
High-copper alloys: Copper content of cast alloys is total refined number. The historical production of
at least 94%; copper content of wrought alloys is 96% refined secondary copper in the United States for the
to 99.3%. This class includes the cadmium, beryllium, years 1968 through 2011 is shown on Table 7. The
and chromium copper alloys. decreased recovery of secondary copper since 1980,
from 30% to 3% in 2010 can be observed on Table 7.
Brasses: Copper alloys containing zinc as the
principal alloying element. There are 3 families of Copper Anodes for Plating. Copper anodes are
wrought brasses and 5 families of cast brasses. produced by ingot makers and foundries in several
EnviroBrass I, II and III were recently introduced in shapes designed for ease use in plating. Copper
1999 as lead-free alternatives to the leaded-red anodes that contain phosphorus are designed for use
brasses used in plumbing. These lead-free cast red in copper sulfate plating systems. Pure copper anodes
brasses contain bismuth and selenium as principal are used in copper cyanide and other alkaline plating
additives. systems. Selecting the correct anode for plating
depends on the following characteristics: Anode area
Bronzes: Copper alloys in which the principal alloying and copper concentration; the size and shape (balls,
element is usually tin, and which contain other metals nuggets, bars), the potential for bridging (caused by
such as aluminum, lead, phosphorous, and silicon, but small baskets and large nuggets), sludge build-up, the
not zinc or nickel. grain structure of the anode, the phosphorus content
and lastly, the preparation of the anode (cleaning).
Copper Nickels: Copper alloys with nickel as the
principal alloying metal. Black copper. Black copper is an intermediate
product produced in a blast furnace from low -grade
Copper-nickel-zinc-alloys: Copper alloys containing scrap. Black copper still contains some iron and zinc
nickel and zinc, as the principal and secondary along with most of the tin, lead, and nickel of the
elements; commonly known as nickel silver. charge. A typical black copper composition is 75% to
88% copper, 1.5% tin, 1.5% lead, 0.1% to 1.7%
Leaded coppers: Cast copper alloys containing 20% antimony, 3% to 7% iron, and 4 to 7% zinc.
or more lead, usually a small amount of silver, but no Traditionally, this material can be refined in a scrap
zinc or tin. converter with the addition of liberal coke to the
charge, which adds extra heat, provides a mildly
Special alloys: Copper alloys with compositions not reducing condition, and facilitates the removal of zinc,
covered by the above descriptions tin, and lead. Copper anode is then poured for further
refining in an electrolytic tank house. Slag, produced
Master alloys and hardeners are also produced by a as a by-product, may contain 1.5% copper, or more,
select group of ingotmakers for use by others in and can be granulated and sold as aggregate, or
performing certain functions in their melt. Master reprocessed when the copper content is high enough.
alloys usually contain 10-15% of the desired metal
and the remainder is copper. They perform the Copper Chemicals and Powders. Most copper
function of making the addition of potentially difficult chemicals made in the United States today, such as
metals easier to a melt. Master alloys are produced as the copper oxides and hydroxides and copper sulfate,
shot or ingot form and are used as a melt addition to are derived from processing copper scrap, copper
deoxidize, harden, improve fluidity or control sludge, or from the process waste liquors associated
composition in many base alloys. For example, with refining copper, copper etchants, brass pickle
phosphor copper master alloy is used as a deoxidizing solutions, and other metal processing. Generally, the
additive in making copper tube. purer, less contaminated forms of scrap are preferred
for making chemicals to avoid inclusion of deleterious
Refined Copper. According to data collected by the metals. Even so, some hydrometallurgical processes
U.S. Geological Survey, 39,000 tons of refined copper permit the use of some types of mixed scrap, such as
was produced from scrap in 2011 down significantly copper-plated steel, and printed circuit boards.
from 460,000 tons produced in 1993. Refined Copper powders are also made from refined metal
products formed include cathode, ingots, billets, shot derived from scrap. Copper powder and copper
(small metallic pellets), wire bar and continuous cast sulfate production in the United States is shown on
rod. In addition, only about 1,000 tons of copper Table 10. Trade in these products are shown in
powder was also produced from scrap in 2009. Table Tables 10A and 10B.
12 shows the manner in which copper is extracted
from scrap and the form of recovery from 1999 According to the U.S. Geological Survey, copper
through 2009. Owing to the few plants actually fire- sulfate production was down to 22,400 tons in 2009.
refining, this data is currently withheld by the reporting This continues the significant decline in production
agency (U.S. Geological Survey), but included in the that is down from 33,200 tons in 1989, and from about

20
55,000 tons produced in both 2000 and 2001. A drosses from melting furnaces can run 20% to 65%
copper sulfate production facility closed during t2004 copper and contain notable amounts of other metals
when Griffin Corp closed its secondary chemical plant such as nickel and zinc. Grindings may be as much as
in Texas. In 2006, Phelps Dodge started a new 100% metal, and contain 10% to 76% copper. Many
primary leach, 40 million- pound, copper sulfate plant of these residues contain valuable byproducts other
at Sierrita in Arizona. Exports of copper sulfate have than copper, such as precious metals, tin, antimony,
increased since 2005 to around 8,000 tons (gross lead, nickel or zinc, for example, which can be
weight) in 2010. Imports of copper sulfate have recovered and upgraded.
decreased slightly over the same period, from 56,000
tons in 2004 to about 42,000 tons in 2011 (See Table Copper slag resulting from fire-refining can run up to
10B) 65% copper, making them highly desirable and
marketable products. This is especially true of slag
Copper powder production from scrap has ranged resulting from fire-refining no. 1 scrap, where there
between 8 tons to 11.7 thousand tons in recent years, are few associated deleterious metals. However, more
but was about 600 tons in 2009 (USGS 2009 MYB). metals may result in the slag than is desirable from
A major decrease in production occurred in 2003, cleaning up less pure scrap. These slags may require
according to data published by the USGS (See Table further metallurgical treatment to recover the valuable
12). Even so, total copper powder exports (HTS by product metals. High silica slag has been used for
740610-20) were as high as 12,250 tons in 2005 (See many non- metallurgical purposes when they are free
Table 10A) , but have been decreasing since this of deleterious elements. Among other uses, slag has
time. Total copper powder exports were around been used for the production of lightweight aggregate
8.500 tons in 2011. About 4,000 tons of copper and rock wool.
powders (both flakes and non-lamellar) were imported
in 2011, but had been as high as 4,600 tons in 2006. In making some master alloys, special types of
residues are generated. In the case of making
According to Queneau and Gruber (1997), about phosphor copper master alloy, the dominant residue
13,320 metric tons of contained copper per year was contains phosphoric acid. Most of the phosphoric acid
being extracted from copper-based scrap as by-product thus formed is collected and sold to
chemicals each year during the 1990s. The USGS fertilizer manufacturers for use in making fertilizers.
(2008 Minerals Yearbook) reported copper recovered
from scrap in chemical compounds as 5,000 metric Some brass mills process their own pickling solutions
tons in 2008. This copper was produced as copper to recover copper by electrolytic processes. In recent
oxides and hydroxides, copper sulfates and other years, there have been several hydrometallurgical
copper chemicals extracted hydrometallurgically from plants that have thrived on processing other
copper-bearing scrap. In addition, a small amount of companies’ sludge and residuals for copper, zinc,
low-grade cathode is produced from electrowinning selenium and tellurium and other metals. A wide
pickle liquors and sludge. According to U.S. ITC trade variety of metals and other products are recovered
data, exports of copper oxides and hydroxides have from chemical waste generated by various metal
been increasing since 2003, and were almost 28,000 working industries, such as printed wire board
tons per year in 2010 and 2011. Destinations were manufacturers, electroplating shops, chemical milling
China, Canada, Korea, Sweden, Singapore, Portugal operations, brass mills, and rotogravure plate
and the United Kingdom. Imports (see Table 10B), on producers. Problems associated with landfill disposal
the other hand, were extremely small. Copper of waste materials are avoided by taking advantage of
hydroxide imports were less than 1,000 tons per year the benefits of recycling at these hydrometallurgical
between 2007 and 2010. This would indicate that plants.
domestic annual production of oxides and hydroxides
was at least 28,000 tons in 2010 and 2011, if all Waste treatment plant sludge may contain 15%
production was presumed to be exported. copper and a 1% to 2% zinc content. Nickel dross
from copper/nickel alloys may run as high 40% copper
Secondary Copper By products. In the process of and 6% nickel, making it a valuable market material.
Ingotmaking, fire-refining and casting of copper and its Copper and brass drosses may run as high as 55%
alloys, some low-copper or mixed scrap materials are copper and contain notable amounts of other metals
generated, such as: scalper and other dusts, such as antimony, zinc, tin and nickel. Scalper dusts
grindings, mill scale, drosses, skimmings, ashes, slag generated by scalpers that remove copper oxide from
and other residues. Most of these residues are mill products may also contain enough copper to be
marketable, or can be used and recycled at the plant recoverable and are often recycled within the plant of
of generation. Scalper scrap and dusts generated in origin.
the process of cleaning billet and other pure copper
forms may be entirely copper. Copper skimmings and

21
Baghouse Dusts. Baghouse dusts are usually sold materials must pass. At a minimum, all production by-
for their zinc, copper and tin content. About 30% of products being sent to a land fill must pass the
U.S. zinc consumption (James Jolly, 1993) is derived USEPA TCLP test (see Chapter 4, this report) before
from all secondary materials, including flue dust a dumping permit is granted. Even so, at times, the
collected during copper alloy processing. About 86% landfilled material can serve a useful purpose at the
of U.S. recycled zinc in 2004 (USGS 2004 MYB, landfill. For example, some brass mill slags and the
Table 9) was derived from the new scrap generated black glass residue from a slag cleaning process can
mainly in galvanizing and die casting plants and at play an important part in the operation of the local
brass mills. Recycled zinc was used for the production dump as a suitable substitute for sand, which is
of zinc metal and alloys, and zinc oxide, zinc sulfate usually purchased and used to cover a landfill at the
and other chemicals. The Zinc Corporation of end of the day. Spent refractory and furnace brick
America’s plant in Monaca, PA, is the largest were also used in a similar way at some localities.
processor of secondary zinc. Clean new brass scrap
and clippings usually require only remelting. Most of Some materials, such the mildly acid water resulting
the zinc from flue dust is recovered through various from making phosphor copper shot are treated to
pyrometallurgical methods. make an inert calcium phosphate sludge before being
landfilled. Spent sulfuric acid (pickling solutions) that
Bag house dusts collected from the typical blast has already had metals removed from it may be
furnace or cupola used in melting low-grade copper shipped as a hazardous material to another plant for
scrap generally contain (Spendlove, 1961) 58 to 61% treatment and disposal as gypsum in a landfill. Some
zinc, 2 to 8% lead, 5% to 15% tin, 0.5% copper, 0.1% firms specialize in treating spent sulfuric acid for
antimony, 0.1 to .5% chlorine, and some unburned disposal.
carbon. When high (about 65% zinc) in zinc and low in
lead (less than 3% Pb), these materials can be used The most commonly land-filled materials associated
for animal feed and for making fertilizer components. with metal-making are the spent metallurgical brick
Most of the zinc oxide is shipped either in large (2,000 and ceramic materials used for lining the furnaces
lb.) plastic bags (Supersaks), or in metal drums. Some when these are not high enough in metal value to
of the zinc oxide collected, however, may be lower in attempt recovery. These materials also must pass the
zinc (20% to 40%) and higher in some of the less TCLP tests prior to dumping. Most brass mills,
desirable elements. In this case, when they are sent foundries and ingotmakers ship some spent furnace
to another plant for treatment, they may be shipped as brick to the landfill, although some have indicated that
hazardous materials. the material also may be used as road material.
Spent brick may also be purchased by a scrap dealer
Other Metal Recovery. In the process of making for further distribution in the market, used in making
copper-based alloys from scrap, notable amounts of concrete, or may be sold for its metal content. Some
other metals, such as tin, antimony, lead, zinc, nickel firms have indicated that spent furnace brick
and aluminum are also recovered as part of the scrap containing significant cadmium or lead will be shipped
consumed. According to the 2011 USGS Minerals as a hazardous material.
Yearbook, Table 9, brass and bronze ingot production
from scrap resulted in the recovery of 89,200 tons of Description of the U.S. secondary industry. The
copper, 3,800 tons of tin, 5,360 tons of lead, 9,310 main consumers of copper and copper-based alloy
tons of zinc, 106 tons of nickel and 13 tons of scrap are smelters, refineries, ingot manufacturers,
aluminum. Secondary metals content of brass mill and the brass and bronze mills. Brass and bronze
products were estimated to be 578,000 tons of ingot-makers and mills make cast and wrought alloys
copper, 1,360 tons of tin, 2,310 tons of lead, and mainly from brass and bronze scrap. Copper alloy
118,000 tons of zinc, and smaller amounts of other scrap may be supplemented by other materials such
metals. In addition to 41,800 tons of copper recovered as No. 1 copper scrap, small amounts of refined
at U.S. foundries, 1,090 tons of tin, 564 tons of lead, copper, and alloying additives such as tin and zinc
1,370 tons of zinc and smaller amounts of other and master alloys. According to data collected by the
metals also were recovered from copper base scrap USGS (2011 MYB, Table 11)), ingotmakers
sources. accounted for 12.6% of total copper recovered from
U.S. copper-base scrap consumption in 2011, 75% of
Items that go to the Landfill. While most low-grade which was from “old” scrap.
residues have traditionally found markets for further
processing or use, it sometime becomes economically Brass mills make wrought alloys poured in shapes,
impracticable to further process a material, or for such as billet and slab, that are then fabricated to
economic reasons, to find a buyer for the materials. In finished mill products, such as sheets, tubes, rods,
these cases, these materials are sent to a landfill. The and pipe. Brass, copper tube, and wire-rod mills
kind of landfill selected is determined by the tests the accounted for 75% of the copper recovered from

22
copper-base scrap in 2011, only 2.5% of which was dollar and a deteriorating competitive position. These
estimated to have come from old scrap. Brass mills useful, workhorse furnaces were replaced in the
use purchased copper alloy scrap and No. 1 copper primary copper industry with flash furnaces that
scrap along with significant quantities of home- depend upon a high sulfur content in their feed for
generated scrap, refined copper, and alloying efficient operation. This action not only cut the need
additives such as slab zinc, lead, tin, and nickel. No. 2 for copper scrap by the primary smelters, but it also
and lower grades of copper scrap are usually refined trimmed the potential capacity available for processing
before use by the mills. Copper tube mills utilize a low-sulfur, low-copper ashes and residues. The
higher percentage of “old” scrap than brass mills, but reverberatory furnaces also began to disappear in the
demand a high quality number 1 copper scrap from secondary industry for similar reasons. The large
dealers and scrap preparers when a refinery is not secondary smelter at Carteret, New Jersey closed
associated. during this period owing to environmental
requirements and poor markets of the time. Air quality
Refiners use both low-grade and high-grade scrap as standards forbid the burning of associated materials to
raw material. Low-grade scrap is treated by a series of old scrapped metal, such as plastics and circuit
pyrometallurgical operations followed by electrolytic boards associated with electronic and electrical
refining. The electrolytic cathodes are then melted and scrapped items, making it nearly impossible to
cast into various shapes by the mills. Higher grades of process these materials by smelter. Although replaced
scrap can be introduced in the later stages of in part by rotary and submerged arc furnaces and
processing. For example, No. 2 copper is generally improved air-particle capture systems, capacity has
introduced before the anode melting step that is nearly ceased in the United States for processing low-
required before electrolytic refining in a tank house. grade copper scrap and residues.
No. 1 copper may be either fire-refined or introduced
at the cathode-melting step, as a substitute for The Nassau metals facility in Gaston, South Carolina,
cathode. Refineries accounted for only 4% of copper which was based on the need to process-scrapped
recovered from copper scrap in 2011, 49% of which wire from AT&T operations, was purchased in the
was from “old” scrap. early 1990's by Southwire. For several years,
Southwire operated both its Carrolton, Georgia and
The U.S. copper industry has undergone significant Gaston, South Carolina secondary smelters and
changes since the early 1980's. The extent of this refineries. However, in 1995, Southwire closed the
change in productive capacity is shown in Figure 8. Gaston plant to concentrate its recycling efforts at
Most U.S. reverberatory furnaces closed in the early Carrolton. In 1999, Southwire announced its intention
1980's in response to environmental pressures to to sell its Carrolton plant and, by 2000, had closed
clean up the air, as well as to cope with the strong both its smelter and electrolytic refinery associated

Figure 8. Trends in U.S. Copper Sm elter and Refinery Capacitie s

(Thousand Metric Tons, Copper)

1982 1989 1994 2004 2010

Secondary
315 481 511 0 0
Smelters

Secondary
545 315 311 123 123
Refineries

Reverb.
1526 474 210 0 0
Smelters

Primary
Flash 173 868 1315 900 710
Smelters

23
with its wire rod plant in Carrolton, Georgia. associated with its operations. The Chemetco site was
also added to the Superfund list, but was archived in
In 1996, there were 7 primary and 4 secondary late 1987. (See Appendix B) According to the USGS,
smelters, 8 electrolytic and 6 fire refineries, and 14 U.S. copper smelter and refinery production fell in
primary electrowinning plants operating in the United 2000 by 42% and 26%, respectively, compared with
States. Two of the electrolytic refineries were 1998. The loss of capacity and the effect of lower
dedicated to two of the secondary smelters; prices on scrap availability also impacted the
processing anode made from scrap. Several of the availability of copper from secondary sources.
primary smelters and refineries also processed some
scrap and secondary anode. The U.S. fire-refiners There continued to be generally a shortage of scrap
processed only scrap. In addition, there were about 23 for fire refining in 2003. Although the fire-refinery at
ingot makers, 53 brass mills, 15 wire rod plants and Warrenton, Missouri had closed in 1999 and reopened
about 600 foundries, chemical plants and other again in 2000 under new ownership, it was to close
manufacturers that consumed copper scrap in the briefly again in 2003, but was operating again in 2004.
United States. In September 1996, the Franklin There would appear to be still a large number of
Smelting and Refining Co. in Philadelphia, a relatively nonferrous foundries, but only the strongest of the
small secondary smelter with capacity to produce ingot makers have done well under the difficult market
about 15,000 tons per year of blister copper closed as conditions of the past few years. The ingot maker of
a result of the high cost of environmental compliance. Lavin & Sons closed at North Chicago during 2003.
It soon became a Superfund site (see Appendix B),
along with many others of the same era. Most high-grade U.S. copper base scrap is
consumed at brass and copper sheet and tube mills.
Cerro Copper Products and Chemetco in Illinois and One copper wire rod mill has a direct cast operation in
Southwire in Georgia once operated secondary conjunction with fire-refining its own wire mill-
smelters. Chemetco produced anode for sale to generated scrap. Although it is estimated that there
others for electrolytic refining. Cerro had a completely currently are about 45 primary brass and tube mills, it
internal process dedicated for use in its associated is difficult to count the actual number since these have
copper tube plants and Southwire produced copper tended to change ownership as well as to expand the
for use in its wire rod mill. In April 1998, Cerro Copper number of plants under the same company name. It is
suspended operations at its 40,000 ton-per-year sometimes also difficult to separate downstream mills,
electrolytic refinery and associated secondary smelter, such as rolling mills, from those that process metal to
but retained use of its 30,000 ton-per-year fire refinery make semifabricates. Only plants that melt raw
until 2001. The company now uses cathode rather material to make primary forms are considered
than scrap as its raw material. The Sauget and “primary” brass or tube mills. Reroll and redraw mills,
Cahokia areas in Illinois were proposed in 2001 to the or mills that operate with imported basic shapes are
National Priorities List (NPL) of the Superfund. This not included in the primary mill lists. One copper rod
site includes wastewater from Cerro Copper Company mill closed in Chicago during 2008.
and the Monsanto Chemical Company (see Appendix
B). Though in 2003, there were still five secondary In 2011, Steel Dynamics Inc (SDI), a Fort Wayne-
fire-refiners, the last of the secondary electrolytic based steel producer announced plans to build a
refineries, at Southwire, closed in 1999. secondary copper smelter in New Haven, Indiana.
This was to be a partnership with the Spanish firm La
In addition to continued retraction of the secondary Farga Group. The joint venture (SDILaFarga LLC) will
industry in 1999, three of seven U.S. primary smelters produce copper with products exclusively from copper
also closed in response to lower copper prices and scrap. (Recycling Today, Aug. 2011, p. 86) . The
market surpluses, and remained closed through 2003. plant is expected to be operational by mid-2012.
By 2006, U.S. primary smelter and refinery capacity
had declined to 700,000 tons (see Table 8) and 2.1 Brass Mills. U.S. primary brass mills (a generic term
million tons, respectively, owing to permanent that includes copper tube and sheet mills) have been
closures. Four primary electrolytic refineries and 14 concentrated in the middle and northeastern United
solvent extraction-electrowinning (SX-EW) facilities States. The largest brass mills are located in Missouri
operated during 2006. and Ohio. The following is the number of brass mills
operating in the United States, by State:
Difficult times had come for the secondary smelters,
stemming from the low copper price, high cost of Ohio (4) Missouri (2)
environmental compliance and the cost-squeeze that
these two had created. In 2001, the smelter at Michigan (2) Tennessee (3)
Chemetco in Illinois closed. Chemetco also had been
Texas (1) Alabama (1)
under suit for potential water contamination

24
New York (2) Oklahoma (1) ingotmakers also purchase significant quantities of
skimmings, grindings, high-grade drosses and other
New Jersey (4) Rhode Island (1) by-products for their metal content. There are about
Illinois (5) Mississippi (2) 21 currently operating ingot makers, down from the 28
counted in 1991. Two plants closed in 2003 and 2004.
Pennsylvania (5) Connecticut (4) The active plants are concentrated near the industrial
centers of Chicago, Los Angeles, and the eastern
North Carolina (1) Iowa (1) United States (Table 14). Ingot makers are
consumers of a wide variety of copper and copper
Virginia (1) Kentucky (2)
alloy materials and other metals. Most U.S.
Arkansas (1) ingotmakers are independent, largely family-owned
and operated businesses.
It should be noted that reroll, or redraw mills are not
included in the above list. About 16 brass and tube Secondary Smelters and Refiners. From a total of 5
mills have closed in the United States since 2002. plants in 1991, there currently is no secondary
See the list presented in Table 13A. There are smelting plant operating in the United States that is
apparently no brass or tube mills remaining in capable of processing the lower grades of copper
California, Indiana, Rhode Island or Massachusetts. scrap. The last operating plant in Illinois closed in
2001. There are no operating secondary electrolytic
A Chinese-based company, Golden Dragon Precise refineries. One fire refining plant, located in
Copper Inc., announced it would build a $100 million Warrenton, Missouri, produces refined copper ingot
copper tube mill in Thomasville, Alabama. and wire bar from scrap. This plant closed in early
Construction was to begin in May 2011 and be 1999, reopening in 2000 under new management,
completed in 18 months. (Recycling Today, Apr. closed again briefly in 2003, but is currently operating.
2011) Four fire-refining furnaces are associated with tube
and wire-rod plants, making a total of 5 fire-refineries
Foundries. Foundries are mostly small, family-owned remaining in the United States since 2001.
operations located near major industrial centers, such
as those in Illinois, Alabama, Indiana and Wisconsin. Hydrometallurgical Plants. A number of plants in the
Foundries, as a rule, do not produce alloy ingot for United States have created thriving businesses based
making their products. Even so, there are a few large on hydrometallurgical processing of secondary by-
foundries that have an associated ingot making products produced by other metal production and
facility. Virtually all foundries remelt the gate scrap metal finishing companies. Some of these companies
and the sprues, risers and rejected castings scrap are listed in Table 14. Using circuit board scrap,
generated during production. According to the U. S. bimetallics , no 2 and no. 1 scrap, most of these
Geological Survey,(2009 MYB, Table 12) about companies produce products such as cupric oxide,
66,500 tons of purchased copper and copper alloy copper sulfate, and copper carbonate. A few
scrap was processed by the foundry industry in 2009. companies produce low-grade copper cathode and
Foundries prefer some types of scrap, such as No. 1 other metal products from wastes, sludges and
chopped wire, because of its small size and easy pickling liquors.
melting. However, most foundries do not have the
capability to perform smelting, refining, and chemical Classic secondary copper feed for hydrometallurgical
analysis of purchased scrap. Therefore, large processing includes:
quantities of scrap cannot be used and the purchase
of ingot with a known chemistry is relied upon. U.S.  Wire choppings, mill scale, mud from wire
foundries consumed 58,500 tons of copper alloy ingot drawing, tubing, turnings and grindings,
in 2009, and 49,500 tons of refined copper. In effect, clips and leaded cable.
foundries are remelters and producers of engineering
shapes. Although 100% ingot charges may be used,  Scrapped brass and bronze such as
charges comprised of combined ingot, returns, and plumbing fixtures
scrap are not uncommon. Experience, the quantity of
shop returns, and the cost of available raw materials  Auto radiators
will dictate the exact proportions.
 Shredder pickings from automobiles
Ingot Makers. These plants produce a wide variety of  Spent etchant and pickling solutions
copper and copper alloy and master alloy ingot for
foundry, brass mill and other industry consumption. In  Circuit-boards
addition to purchasing a large proportion of the "old"
copper and copper alloy scrap collected each year,

25
  Spent catalyst, including metallic copper and skimmings generated are reprocessed in house.
Home scrap data will not appear in the published data
 Waste water and other sludges (F006 on purchased scrap since it never leaves the plant
wastes) 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. 2009 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 (2009
and oil. The metal-laden sludges (F006 wastes) Minerals Yearbook and Mineral Industry Surveys).
generated at these plants provide a source of copper
and other metal raw material for some As a point of interest, it can be noted on the flow sheet
hydrometallurgical recovery plants. that about 2.4 million tons of mill and foundry products
equate to about 790.000 tons of new scrap returned
for use in 2011. 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 but other products
ingot maker, brass mills, foundries to final products. such as about 25,000 tons per year of copper oxides
The domestic sources for low grade ashes and and hydroxides are also produced and generally
residues are the processing facilities (ingotmakers, dissipated where used. A large proportion of U.S.
secondary smelters & refineries, brass and wire mills) produced hydroxides and oxides are exported
themselves. Some low-grade ashes and residues are annually. See Table 10A, where about 26,320 tons of
also imported and exported. Not shown on this chart, oxides and hydroxides were exported in 2011.
but also important, is the significant amount of run-a-
round, or home scrap that is used by the industry. At
tube mills, this in-house scrap can amount to as much
as 30% of the material first poured to make billet and
then processed to tube. Since this material generated
within the plant can be easily remelted, or fire-refined,
much of the home scrap generated is not sold to the
open market. Although about 28% of the skimmings
and slag and other by-products generated are
processed in house, most enter the purchased scrap
market. The home scrap environment is similar at a
brass mill that is fully integrated. The clean copper
alloy scrap generated from milling and edge trimming
operations is recycled back to the brass mill casting
shop, where it is remelted and cast into cakes and
other forms for further use.

A current trend in response to the disappearing

secondary smelting industry has been the effort by
some ingotmakers and brass mills to process their
own by-product skimmings, slag and other residues. It
has been estimated that as much as 28% of the slag

26
27
CHAPTER 2: however, copper recovered from total U.S. scrap
consumption has dropped to around 774,000 tons per
Overview of Scrap Sources year in 2009. In addition to the many copper and
and Types 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 electronic scrap,
Scrap Sources and Types
printed circuit and other clad materials, and metal-
laden waste liquors. The markets for these products
The Institute of Scrap Recycling Industries, Inc. (ISRI)
are different from those for the purer grades of
recognizes about 53 classes of copper and copper
copper-base scrap, because they must be
alloy scrap. The organization publishes a scrap
reprocessed, smelted or electrowon to obtain the
specification circular that details guidelines for
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
shows a list of generalized chemical compositions for
items.
various scrap types.

Several alloy scrap type groups, such as mixed

unsweated auto radiators (Ocean), provide sizeable
amounts of copper scrap each year. Other important EPA Secondary Product Definitions
sources of scrap, by volume, include cartridge cases
(70/30 brass) from the military and other yellow brass The U.S. Environmental Protection Agency (EPA)
castings, rod turnings and rod ends. Significant plays such a big role in how the secondary industry
amounts of unalloyed copper are derived from carries out its business, it is worth reviewing that
discarded wire, bus bars, clippings and tube. A agency’s definitions for secondary products.
relatively new scrap type, derived from According to the EPA (40 CFR Chapter 1, 7/1/98 Ed.
aluminum/copper radiators, also is finding use among (261.2)), a material such as process slags and
scrap remelters. As shown in Table 16, copper residues is reclaimed if it is processed to recover a
derived from new and old aluminum-based scrap has usable product, or if it is regenerated. A material is
been increasing significantly since 1980. Copper from used or reused if it is either:
aluminum-based scrap increased from about 35,000
tons in 1980 to 71,600 tons in 2007. Copper from all (1) Used as an ingredient (including as an
scrap sources increased from 886,000 tons in 1950 to intermediate) in an industrial process to make a
a peak of nearly 1.5 million tons in 1997. Since then, product. However, a material will not satisfy this
condition if distinct components of the material are

28
 recovered as separate end products. For boards (30% copper, 68% fiberglass, 2% tin and lead)
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 2011 were: No. 1 copper, (39%); No. 2
limited to, scrap metal that has been baled, shredded, copper (8.5%); yellow and low brass (29%);
sheared, chopped, crushed, flattened, cut, melted or automobile radiators (2.4%); red brass (3.7%);
separated and sorted by metal type. It also includes cartridge brass (9.7%); and low-grade ashes and
fines, drosses and related materials that have been residues (2.4%) (see Table 17B). A wide variety of
agglomerated. Shredded circuit boards being sent for other alloy scraps makes up the remaining 7.7%.
recycling are not considered processed scrap metal. Brass and copper sheet, wire and, tube mills
They are covered under the exclusion from the processed 88% of the No. 1 copper and most of the
definition of solid waste for shredded circuit boards cartridge cases and yellow brass, while the fire
being recycled. (261.4(a) (I3). refiners and ingot makers processed 77% of the No. 2
scrap and most of the auto radiators and red brass
In a document issued March 1, 1990, EPA clarified scrap (USGS 2011 MYB, Table 10). About 20% of the
the reclamation of unused, off-specification printed scrap consumed in 2011 was lead-bearing, including
circuit boards. When reclaimed, unused printed circuit auto radiators using lead solder (22,400 tons), red and

29
leaded-red brasses (34.600 tons) and leaded-yellow statistics. One might use a percentage calculation
brasses (128,910 tons). applied to the unalloyed copper scrap exports based
on the ratio of No.1 to No.2 consumption for the years
In recent years the amount of No. 2 scrap reported as before the demise of the smelter industry. In 1988, the
consumed by the U.S. industry has been decreasing. ratio of No. 1 to No. 2 scrap consumed by the U.S.
The decrease in No. 2 scrap consumed by U.S. industry was about 1:1, but the ratio has been
industry is related to several changing factors. One deteriorating since that time (see Table 17). In 1990,
such factor is the significant increase in better quality No. 2 was 45% of total unalloyed scrap consumed.
wire and cable recovery by scrap choppers and Using 45% applied to 2004 exports (325,000 tons) of
processors. More chopped wire is converted to No. 1 unalloyed scrap yields a total of 146, 250 tons of
scrap quality than has ever before been possible, number 2 scrap exported. Recent data indicates that
owing both to an increase in this type of activity and to the percent of number 2 scrap exported in 2004 was
better technology. Other factors included the lower much higher.
prices of 1998-2003 (Table 1) and increased export
competition for such scrap in more recent years. Recent U.S. trade reports have been breaking down
scrap types exported. In 2004, the Harmonized
The consumption of No. 2 scrap decreased markedly Trade (HTS) items were reviewed and revised by the
at U.S. plants since 2002, as a result of secondary U.S. government. HTS 7404000020 (waste and
smelter and electrolytic refinery closure. Some primary refined scrap from refined copper) has been broken
smelters have been accepting limited tonnage of No. into two Number 1 scrap categories (HTS
2 scrap. However, apparently, scrap exports were 7404000010 and --15), two Number 2 scrap
filling the gap left by the loss of U.S. capacity, as categories (HTS 7404000025 and –30). The results of
discussed in the previous section on international the new trade breakouts are shown for 2005 to 2009
trade. It has been difficult to quantify the total volume in Table 8A of this report. From this table, it can be
of No. 2 scrap recycled each year, since the only seen that Number 2 scrap comprised a large share
statistics reported for the United States are (about 77%) of the unalloyed scrap exported. Of the
consumption-based. Scrap traders are not surveyed. total of 500,561 tons of unalloyed scrap exported in
Adding exports to the No. 2 scrap consumption 2011, Number 2 scrap comprised 76% of the total.
statistics also is not a certain solution to compensate About 381,234 tons of number 2 scrap was exported
for the apparent loss, since these materials have not in 2011. These scrap exports yield an average of
been always specifically defined as to type in trade about 32,000 tons per month that can be added to the

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 08 09 10 11
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 20 20 20 20

Unalloyed Red Brass Yellow Brass 1/ Cartridge Brass Bronzes

Low-grade scrap 2/ Auto Radiators Nickel Silv er

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, see Table 17B, this report

30
domestic consumption of 3,400 tons per month for a per year, down significantly from 124,000 tons in
total of 35,400 tons per month of number 2 scrap, 1998. This compares with 161,000 tons per year of
compared with an estimate of 51,000 tons per month low-grade scrap and residues processed in the United
that was common domestic consumption in 1997 States in 1992 and 1993. Consumption of low-grade
(See Table 17B). residues was reported to be 22,900 tons, according to
the U.S. Geological Survey (2011 MYB).
A few trends in consumption rates, shown in Table 17
and in Figure 10, for certain types of scrap are worth Scrap consumption was lowest during the recession
mentioning. The amount of auto radiators (does not years of the middle 1970s, early 1980s, and again in
include aluminum/copper radiators) consumed by the 2001–2003. Some of the underlying causes for these
U.S. industry has ranged between 31,000 tons and trends are discussed in Chapter 1 and in Appendix A.
104,000 tons per year since 1970, with the peak In particular, lower copper prices and the closure of
occurring in 1988. That amount has been steadily adequate processing capacity for domestic copper-
decreasing since 1988 to the current rate of around bearing scrap has been responsible for many of the
22,400 tons. Auto radiators were reported in tight observed declining usage trends. In recent years,
supply by ingot makers during 2009. Yellow foreign competition for U.S. scrap materials also has
(including leaded-yellow) and low-brass scrap been a considerable factor bearing on the reduction in
consumption steadily increased through 2000. Since scrap consumption by U.S. industry.
2000, however, yellow brass consumption has
decreased to only 274,930 tons in 2011. The yellow Scrap available for collection was also impacted by
brass categories were lumped together in Table 17 to the slowdown in domestic manufacturing and
allow for possible definition changes over the period of construction activity over the period 2007-2011.
statistical collection between types of yellow brass Construction activity in North America began to taper
scrap. The amount of bronze scrap consumed has down after a peak reached in 2007, even before the
ranged between 18,000 tons and 32,000 tons per year collapse of markets in late 2008. Since then,
since 1970. Although aluminum bronze scrap has construction has dropped severely. New construction
remained at a more or less constant rate of contract values were reported (Recycling Today,
consumption, the number of plants using it has December 2010) to be $506. 9 billion for the first 9
diminished, resulting in this statistic being withheld by months of 2007, but was valued at only $314.6 billion
the government statistical collectors since 1991. for the same 2010 period. This performance has
played out in the form of less demolition scrap and
Cartridge brass consumption reached 131,000 tons less scrap from new construction or renovation
during the last three years of the Vietnam conflict projects over this period.
(1970–1973). Since that time, cartridge brass
consumption has remained in the range of 46,000
tons to 94,000 tons, with the exception of the 1988–
1990 period, when consumption reached as high as Volumes of Scrap Generated
140,000 tons during a time of temporary military
buildup for Desert Storm. The slight increase in Since 1906, at a rate ranging between 10,000 tons
cartridge brass consumption from a low of 36,000 tons and 1.6 million tons per year, the calculated U.S.
in 2001 to a high of 94,000 in 2006 may be the result cumulative consumption of copper from old and new
of the military activity in Iraq and Afghanistan. In 2002, scrap amounted to 85.3 million tons by 2012 (See
cartridge brass consumption nearly doubled to 70,900 Table 6A) Of this amount, 56.6% (47.5 million tons)
tons from the low point of 36,400 tons in 2001. consumed was from old recycled scrap. More will be
Cartridge brass consumption was 86,659 tons in 2004 discussed about these statistical relationships in the
and more than 94,000 tons in 2005 and 2006. In next section on life cycles and the scrap reservoir.
2010, cartridge brass consumption was up to 98,200
tons. In 2011, (USGS, 2011MYB, Table 6) recycled copper
was derived 81% from purchased new scrap
The amount of marketed low-grade scrap processed generated in the process of manufacture and only
in U.S. plants has been decreasing since 1985, as 19% from old scrap derived from used products.
indicated by data collected from the industry by the Copper from scrap recovery exceeded l million tons
U.S. Geological Survey and U.S. Bureau of Mines per year in 1965 and continued to be above this level
(Table 17 and Figure 10). While the amount of low- through 2002, dropping to 800,000 tons in only one
grade, copper- bearing materials consumed in 1998 year (1975). Copper recovered from scrap has been
and 1999 was marginally higher than the previous 4 well below 1 million tons since 2003 (Table 6).
years, it still was only one-third that of the 1970s and
early 1980s. Low-grade scrap and residues consumed
annually since-2007 has been less than 24,000 tons

31
According to the U.S. Geological Survey, a total diminished in recent years, especially since 2001.
802,000 tons of copper was recovered from copper This coincides with the shutdown of US secondary
base and non-copper-base scrap in 2011. Purchased smelters, but is also, In part, a result of secondary
new scrap (Table 7, 2011 MYB) derived from plants recycling more of this type of material internally
fabricating operations yielded about 618,000 tons of where possible. New production methods that have
contained copper, 89% of which was recovered at been implemented specifically to cut down on the
brass mills. A manufacturer may generate more than volumes of residues created have also been
60% scrap in the form of slippings, trimmings, responsible. The goal is, generally, that only the most
stampings, borings and turnings during the processing innocuous and uneconomic material will leave the
of copper and copper-base products into finished plant for a landfill or purpose other than metal
articles. This new, or mill-return, scrap is readily used recovery. The severe drop in domestic market
by brass and copper tube mills to generate new semi consumption of low-grade reflected the closure of the
fabricates. Secondary materials that require minimal last U.S. secondary smelter in 2001.
processing commonly are called direct-melt scrap. In
the United States, direct-melt scrap provided about The data in Table 17 show a distinct reduction in U.S.
705,000 tons (Table 2C), in 2011. New scrap made consumption of low-grade material as purchased
up about 27% of U.S. apparent consumption of scrap beginning in the early 1980s. Reduction in the
copper from all sources (primary and recycled) in use of low-grade material for industrial feed coincides
2011 (see Table 6). Copper in old and new scrap with several events over the period: (1) capacity
together comprised about 33% of U.S. apparent total cutbacks and decreased use of reverberatory
copper consumption in 2011. 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 17 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, for 1998 is similar to
scrap category. These statistics do not include any of the total low-grade, purchased ashes and residues
the materials that are processed in-house as scrap data tracked by the U.S. Geological Survey (see
runaround scrap. Both exports and domestic Table 17B). This observation lends credence to the
consumption reported for low-grade residues have reliability of both sets of data. The total by-product

32
production shown in Table 18 is larger than the oxide dust, baghouse dust and some furnace and
purchased scrap data of the USGS, owing to the fact refractory bricks. Elements such as cadmium and lead
that some home or runaround scrap is included in usually caused the product to be classified as
Table 18, but not in the USGS data. It was estimated hazardous, when these were present in significant
that at least 28% of the skimmings and slags are amounts.
recycled in-house, as indicated by the reports.
The average product yield from certain melts was the
Not surprisingly, the brass mill group (including tube subject of a 1961 U.S. Bureau of Mines research
mills, wire rod mills and their associated refineries) report (Spendlove, 1961). According to this study, the
was the source for most of the by-products surveyed. following products may be expected from processing
Next in size, and commensurate with its share of 190,000 tons of brass and copper scrap in a tilting,
scrap consumed and types of processing, was the cylindrical reverberatory furnace. The melt had the
ingot maker group. Though their numbers are many, following average composition: 84.5% Cu, 4.4% Sn,
the total amount of by-products generated by copper- 5.25% Pb, 5.4% Zn, 0.15% Fe, 0.22% Sb (from
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

33
can be put back into the production process directly. It foundries restrict the use of these materials to
is otherwise sold as No. l or No. 2 scrap for confined areas.
processing and use outside the plant of origin. Wire
mills must be more particular with in-house-generated
scrap, requiring a fire-refining step before
reintroduction to an Asarco shaft furnace for recasting. Use of Purchased Scrap
Items such as flue dusts, drosses and other minor
materials generated are not usually runaround, since When purchased scrap is used, a complete analysis
these items may be shipped to other companies for of each melt is necessary to assure freedom from
reprocessing. Home scrap ceases to be runaround contamination. Some forms of purchased scrap are
scrap when it is sold to another plant for further relatively reliable such as heavy copper wire, bus bar
processing. The scrap is then referred to as new or automotive radiators. Obsolete old scrap from
purchased scrap, entering the secondary materials certain sources and applications also may be
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- increased use by the U.S. consumer of imported
product scrap generated at smelters and refiners, faucets, tube and other products made from foreign-
such as slag, flue dusts and spilled metal, can be made alloys has increased the need for constant
partially or wholly reprocessed in-plant. Some, such vigilance of the scrap purchased. Most ingot makers
as the flue dusts generated, must be sold or shipped and mills must have sophisticated procedures for
to other facilities for treatment and disposal. Slag is analyzing purchased scrap, adding to the cost of
often sold into a direct use market, but depending using this material. Purchased customer-returned
upon its metal content, may also be reprocessed in scrap to brass mills can usually be presumed reliable
the home plant, sold to other smelters or locally for direct melt, but even these must be closely
landfilled. Some slag resulting from fire refining of monitored. Product specifications call for a very low
scrap can contain as much as 65% copper and, thus, content of certain elements, such as aluminum and
is a very desirable 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
be building up in the return materials. Each of these
Life Cycles and the Theoretical
can contribute to casting defects and are not normally Resource for Scrap
used without preparation. With successive remeltings,
there will be a decided trend toward the gradual loss The availability of secondary copper is linked with the
of volatile elements, such as zinc, as well as an quantity of copper consumed and product life cycles.
accumulation of contaminants, such as iron. Many estimates for life cycles have been made for
Depending upon melting and subsequent individual products. Product life cycles may even vary
deoxidization practices, the level of residual from country to country according to construction
phosphorous in the melt may rise to undesirable methods and concepts. However, copper in electrical
levels. Thus, a consistent monitoring of internal scrap plants and machinery generally has been estimated to
composition should be made before reuse. A average 30 years; in nonelectrical machinery, 15
particularly serious contaminant in the case of copper- years; in housing, 45 years; and, in transportation, 10
tin-lead-zinc alloys is aluminum. Unfortunately, years. The average useful life for copper products is
aluminum beverage cans and foil wrappers may said to be about 25 years before being scrapped and
accidentally find their way into the charge material. entering the market as old scrap.
When this happens, not only are serious problems
generated in the melt, but also such metals must be Keeping these longevity measures in mind, it is not
discarded and resold to a smelter, since their reuse hard to visualize that copper being recovered today is
could cause the same problems over and over. Many from scrapped items that were produced for use about

34
25 years ago. New (manufacturing) scrap, on the first two categories is always possible with adequate
other hand, has a short life of about 30 days, and incentives and technology. Copper has few
domestic manufacturing rates and efficiencies limit its applications that are dissipative in nature, such as in
recovery. This wide difference in turnaround and chemicals, paints and some powders. It has been
availability, in addition to the growing manufacturing estimated (Carrillo, 1974) that in 1970 only 0.5% of
base from which it is generated, has resulted in a total copper consumed was lost and not retrievable.
gradual increase of new scrap versus old scrap Most copper is used in some metal form, easily
collected in the United States since the 1930s (Table recognizable and easily recoverable. Some household
6). The rate of copper consumption in the United products such as toasters, motors, TVs, electronic
States and the world has more than doubled since the equipment, etc., may have been dumped into landfills
1960s. Scrap copper (old and new) has made up in the past, rather than collected or sold for their metal
more than 40% of annual U.S. copper consumption content. However, with the current emphasis on the
over most of this period, only dropping below 40% selection of household and municipal-dump items for
since 1993 (Table 6). recycling, the amount of copper actually placed in a
landfill is probably not only small, but is diminishing.
The current downward trend in scrap copper In 2011, about 5,000 tons (less than .05%) of copper
consumption was coincidental to the significant chemicals produced from scrap may have been lost
increase in consumption of primary (mined) copper out of a total of 942,300 tons of copper scrap
since the early 1990s, and the lower copper prices consumed.
1998 through 2003. Following this trend was the
decreasing rate of semi fabricate production in the The variances in estimates for the amounts recycled
United States since 2000. Semis production was 2.18 are directly related to a lack of reliable data as well as
million tons in 2011, much below 3.9 million tons in to the procedures used for making the estimations.
2000, see Table 10. Scrap comprised only 33% of Because time is always a factor, it has been difficult to
total U.S. copper consumption in 2011(See Table 6). quantify how long a product has been in use and how
much of it was recovered over what time period.
Though copper is one of the most recycled of metals, Some have estimated copper not recovered to be as
some still enters solid waste disposal sites. Copper high as 50% of all products reaching the end of a
that is not recovered from end-use products may be useful life. However, other estimates have suggested
placed in one of three categories: (1) still in use, or that the recovery (recycle or reuse) rate may be in
buried and unaccountable, (2) solid waste disposal, excess of 70% for copper products no longer in use.
(3) dissipated and lost. Recovery of copper from the Because, generally, it has been cost effective to

Figure 11. U.S. and World Copper Resource

for Old Scrap
Pool of Copper Materials In Use

Million Tons, Copper Content

400

357.6 million tons in 2012

300
World Trend

200 U.S. estimated =

100 million in 1972
94 million in 2012

45 million in 1975

100
U. S. Trend

U.S. Actual =86.9 million in 2012

0
41 44 47 50 53 56 59 62 65 68 71 74 77 80 83 86 89 92 95 98 01 04 07 10
19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 20 20 20 20
USEstimated World USActual

Sources: JJolly, Jan. 2013. McMahon, 1965

W orld R es ourc e= C opper mine produc tion inc reas e les s 40% deduc ted for: rec irc ulating s c rap(25%) and proc es s los s es (15%)
U .S. es timated R es ourc e= Primary c opper c ons umption inc reas e les s 25% for annual rec irc ulating c opper.
U .S. Ac tual res ourc e = Primary c opper c ons umption inc reas e les s annual reported new s c rap generated (1864-2009)

35
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 9% of U.S. apparent
The estimated resource calculations made below, and consumption in 2011 (see Table 6A) In 1960,
in Table 6A indicate that more than 64% of total McMahon also estimated about 25% of annual
primary copper consumed in the United States has consumption was new scrap that was generated from
been returned and reused as new and old scrap over fabricating and manufacturing semi finished and
time. This calculated scrap recovery rate was as high finished products. McMahon recognized that new
as 70% between 1989 and 1994, but has dropped scrap copper does not form a reservoir supply to
currently to around 64%. This change undoubtedly is supplement production of primary copper. New scrap
related to the drop in old scrap consumption, as such as defective castings, clippings, punchings,
reported for the United States. The rate of old scrap turnings, etc., represents a circulating quantity of
recovery (56.2%, including exports) from the copper previously accounted for as a supply of
calculated primary copper end-use resource has been primary copper and returned to the fabricating process
decreasing since a peak of 54%, which was reached without reaching the product stage. It is, in effect,
1991- 1993. 100% recycled. Even so, data on the movement of
new scrap have significance as indicators of business
The rate of old scrap recovery is limited not only by activity in the fabricating and scrap reclamation
copper’s long life and its essential uses, but also by industries.
the sensitivity of scrap collection to market prices.
When copper prices are depressed, old scrap tends to The resource estimation procedure adopted by
be less available and is directly related to the cost to McMahon deducts an estimate of 25% annually from
recover and process it. The distinct decrease that is the cumulative series of primary copper consumed.
observed in the old-scrap to new-scrap recovery ratio McMahon (1965, Table 10, p. 77). The estimation
since 1990 (Table 17B) has more than a price procedure also purposely does not include old scrap
relationship attached to it. Since the closing of all in the calculations. Although McMahon does not
secondary and primary copper reverberatory smelters specifically identify the 25% deducted for unused
occurred over this time period, one can only assume primary copper as new scrap, it is here presumed to
that the sharp drop off in consumption of old scrap be the case, based on his detailed description of
over the same period is related to the decrease in scrap relationships. In other words, he presumes that
adequate processing capacity in the United States. only 75% of the primary copper consumed each year
Once sought out for its metal content, this material is goes to the end-use market, and 25% of it does not.
either being exported, or it is not being collected for This copper has not been dissipated, or lost, but has
consumption. U.S. copper and copper alloy scrap been recirculated and recycled in small amounts
exports have increased significantly in recent years every year.
and might logically be presumed to be mostly old
scrap. At the same time, new scrap recovery has McMahon’s calculation procedure provides a resource
been increasing at a rapid pace in tandem with the base of end-use copper from which to retrieve old
higher rate of copper consumption and manufacturing. scrapped items. Using the above estimation method,
the U.S. industry’s contribution to the secondary
Resource Theory and Calculations. Primary (mined) materials reservoir of items in use, or abandoned in
copper forms the only contribution to a theoretical place, has increased from about 14.5 million tons in
accumulating resource base. Most of the copper ever 1940 to around 93 million tons in 2011 (see Figure
extracted from the earth can be determined by using 11). According to McMahon (1965, Table 10, p.75),
primary copper consumption or production statistics about 52% of the end-use reservoir so calculated had
that have been collected and published over time. been returned and reused as old scrap by 1960.
However, scrap, old or new, is excluded as a primary
constituent of the theoretical resource base, since no McMahon’s method for estimating the world resource
new (primary) copper can be generated from it. involved a simple ratio equation based on the
assumption that the rest of the world consumes
According to McMahon (1965), a large reserve for copper in much the same manner as the United
secondary (recyclable) copper, in the form of States. Using this formula with cumulative world

36
copper consumption, as McMahon suggests, yields The resource of available copper in end-use products
some 314 million tons of copper for the resource base for the United States may also be estimated by using
in 2002. This estimation is a little too high, however, actual primary copper and scrap-consumption
because the consumption statistics used for the world statistics reported each year, instead of an estimate
include copper from scrap. for new scrap (Table 6A). A certain amount of new
scrap that is generated as home and mill-return scrap
Since imports and exports between countries are not in the United States is sold to other companies for use
an issue, it is not necessary to use consumption in their semi fabricating processes. In 2010, the
statistics to estimate the end-use (old-scrap) resource United States derived about 27% of its total copper
base for the world. We can use, instead, statistics for (primary plus scrap) consumption from new
either world primary refined or mine production. Mine purchased scrap (Table 6). See also the data on flow
and smelter production are used for this paper sheet Figure 9 for gross weight new scrap returned
because these are the longest, most reliable, (32%) from copper products produced in 2011.
historical statistics available. The primary world end-
use reservoir also does not include the pool of new
scrap that is recycled and reused every year. It has been suggested (Thomas Baack, pers.
Therefore, an estimated 40% is deducted annually Communication 2005) that because new scrap has a
from the world production of primary mined copper to short life span, the potential exists for the same
account for (1) processing losses and (2) for physical quantity to be recorded many times as it
recirculating scrap. Because new and home scrap passes through a production stream during a year. It
are, by definition, almost 100% recycled and might therefore be possible that the real physical
recovered, 25% is deducted for recirculating scrap quantity of new scrap used each time over and over
that, in theory, never reaches the product reservoir in might be a fraction of the total amount reported as
the year that it is generated. Another 15% is deducted used for the entire year. Hence, if the scrap was
from world mine and smelter production for the returned and reused 4 times per year, for example,
process losses incurred in conversion to refined the total value for returned new scrap would be 25%
copper. Using world mine production, the world of the cumulative amount . This would increase the
resource of copper in use, in place or buried was cumulative end use pool by about 30.5 million tons
calculated to have grown to about 357.6 million tons and reduce the new scrap volume significantly.
of copper (Figure 11) by 2012. Application of this applied time philosophy is difficult,
but may be worthy of consideration in future research.

Figure 12. U.S. Copper Resource for Old Scrap

Pool of Copper Materials In Use, 1959-2012

Million Tons, Copper Content

100
Copper used in end use products
83.6 million tons (cumulative primary refined)

80

60
56.8% recovered as old scrap
and recycled (1864-2012

40

20
Old Scrap Recovered 1864-2012
85.3million tons, including exports

0
59 61 63 65 67 69 71 73 75 77 79 81 83 85 87 89 91 93 95 97 99 01 03 05 07 09 11
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

USActual Cum Old+Export Scrap

Source: JJolly, Jan. 2013

U SAc tual = C umulativ e primary c opper c ons umption inc reas e les s annual new s c rap generated (1864-2010).
Old Sc rap C umulativ e = C umulativ e rec ov ery of c opper in old s c rap returned from end us e s ec tor and reus ed, plus c opper in net ex ports of s c rap.

37
Based on reported U.S. annual data, the cumulative These calculations yield an estimated 86.3 million
primary refined copper consumed in the United States tons of copper accumulated over the period 1864
since 1864 amounted to 133.5 million tons by through 2012 as the U.S. resource of copper in
2012(Table 6A). From this initial mined source, a manufactured products in use (Figure 12).
cumulative 85.3 million tons (64%) of copper from old Interestingly, about 56.8% (47.5 million tons) of this
and new scrap had been returned for consumption by adjusted, theoretical end-use resource had been
the industry through 2012. New scrap was recycled at recovered and reused as old-scrap copper (including
rates ranging between 4,000 and 1.6 million tons per exports) through 2012. (Table 6A). Net exports of
year between 1906 and 2012. New scrap made up copper scrap were added to old scrap copper
about 25% of the total copper consumed over the consumed by the U.S. industry to achieve a total old
period (see Table 6). At the same time, old scrap from scrap yield. Calculations related to the cumulative
obsolete end uses was recovered at a rate ranging primary copper resource yield an estimate of about
between 6,000 tons and 613,000 tons per year, 1906 36% of the resource remains in products in use by
through 2012. This resulted in a cumulative 47.5 2012. This is derived by deducting the cumulative old
million tons (56.8% of the end-use resource) of old scrap recycled from the cumulative end-use resource
scrap being returned for consumption by 2012(see of 83.6 million tons. This estimate includes items that
Table 6A). are still in use, buried or, to a much lesser extent,
possibly dissipated. Copper used in chemicals can be
In the United States, old scrap copper estimated to be presumed to have been dissipated, but beyond this,
consumed by industry in 2011 was only 153,000 tons. nothing can be definitively quantified as irretrievably
However, by adding net copper in scrap exports lost. Furthermore, it should be noted that these
(presumed to be all old scrap) to the copper in old calculations do not take into account the growing
scrap consumed by U.S. industry, about 1.1 million amount of copper in end-use products that enter this
tons may have been recovered as old scrap in the country as manufactured goods. The contribution of
United States in 2011. Thus, it would appear that these finished-goods imports to the scrapped products
about 120 times the amount of old scrap recovered for reported and to the U.S. resource of end-use products
use by the U.S. industry, also was exported. An is not easily quantifiable or estimated.
increasing amount of old scrap collected in the United
States has been exported since the mid-1970s. This The rate of old-scrap recovery from the copper end-
can partially explain the consistent decrease over this use resource increased rapidly prior to 1945, when
period in U.S. old scrap consumption, as illustrated in the rate increased in excess of 1% per year, between
Figure 13. 1906 and 1938. The recovery of cumulative old scrap
from the total resource was only about 9% by 1914
Old scrap derived from finished products has but had reached 37% by 1938. The rate of copper in
customarily been considered a new resource of old-scrap recovery has been increasing by a little less
copper in the year of reuse, as it re-enters the than 1% per year since 1945 and has hovered around
manufacturing stream. For the purposes of calculating 50% to 56% of the cumulative resource since 1980
a current year’s copper consumption, old scrap is a (see Table 6A). The annual U.S. contribution to the
legitimate augmentation to available primary copper. copper reservoir of items in use has been increasing
New scrap, on the other hand, is derived from at a rate of 1–2 million tons of copper per year since
manufacturing and processing. It has a short shelf life 1963.
and, in theory, recirculates before ever reaching the
end-use market. As McMahon (1965) points out, new The available copper in the end-use resource may
scrap does not, at any time, form a reservoir supply to seem large but, as discussed above, the potential rate
supplement new copper. To include recirculating new for retrieval in a uniform and reliable way is limited by
scrap in consumption estimates each year by adding it many factors. Of particular significance is copper’s
to new mined copper (primary), would present a long life in many of its end uses. With a recovery life
double-counting problem, as the same (primary) of 25 to 45 years, copper items produced in the 1960s
copper goes through the processing chain over and and 1970s may only be in the recovery process today.
over, never reaching the end-use market. Because of It would appear that a sizeable portion of all copper
this phenomenon, new scrap also is excluded from consumed is still very much in use today. This would
total copper use annually in order to calculate an amount to around 40% of the so-called, end use
estimated primary end-use resource without scrap. resource base, as currently calculated.
This primary end-use resource is the total pool of
copper from which to estimate the percentage return Of all world copper (24.4 million tons) consumed in
of old scrap, which is derived from the copper used in 2012, 33% was from direct melt and refined copper
final products. scrap sources (Table 2A). Of the total 7.9 million tons
of world copper derived from all scrap sources
(Tables 2B and 2D in 2011, only 3.7 million tons were

38
recovered by refining (47%) and might be considered methodology for the estimation of a recycling input
mostly from old scrap sources. Copper from refined ratio (RIR). This recycling input ratio is derived by
scrap comprised about 18% of total world copper dividing the total scrap consumed in a region by the
consumed from all sources in 2011. Another 7% of total semi fabricates produced. The RIR illustrates
total world copper might also be presumed to be from trends in the relative amount of scrap used versus
old direct melt scrap, making a total of 25% of copper primary material in semis production. The RIR
from old scrap sources in 2011. calculation is put into perspective for the United States
in Table 6B of this report and shows a consistent
In a paper issued in 2002, several European analysts decrease from the mid-1980’s through 2000. These
(Spatari, Bertram et al. 2002) traced the flow of statistical trends are the result of several significant
copper as it entered and left the European economy events that have occurred in the United States over
during the course of one year. Russia was not the past ten years or so.
included. Across the life cycle, a net total of 1.9 million
tons of copper was imported into Europe. About 40% In addition to a decreased amount of scrap
of cathode produced within the flow system was consumed, relative to primary material, the U.S.
directly from old and new scrap. It was estimated that recycling input ratio (RIR), as calculated above, has
about 8 kilograms of copper per person enters the been much influenced by the increased amount of
end-use market each year, only 30% of which is in copper scrap exported since 2000. To calculate a
alloy form. They also estimate that the waste more complete picture of U.S. scrap use and
management system in Europe recycles about 60% of recovery, total copper scrap exports must be added to
the copper from “waste.” The net addition of copper to the amount of industry consumed scrap reported.
the end-use “stock” in the copper flow system is about Looking at Table 6B, a striking trend emerges of a
6 kilograms per person per year. They conclude that decreasing recycling recovery ratio (ROR) from 1992
given the in-service lifetime of the applications of forward to 2004. Between the years 1981 through
copper identified in their flow model, most of the 1993, the rate of recovery (ROR) is consistently over
copper processed during the last few decades still 61%, reaching as high as 81% in 1986. From 1993
resides in use, mostly in non-dissipative uses. forward, however, the rate of recovery is shown to
decrease to as low as 46% 1999 and 49.5% in 2002.
The International Copper Study Group recently (2004) The rates have been increasing since 2004, reaching
completed a study on recycling in Western (ICSG’s 91.6% in 2011. The higher scrap recovery ratio
Copper Flow Model on Recycling Ratios in Europe). undoubtedly relates to the higher copper prices since
One consideration outlined in this paper is a statistical 2004 and the influence of higher scrap exports.

Figure 13. Cumulative Old Scrap Copper

In the United States, 1959-2012

Million Tons, Copper Content

50
Total Old Scrap recov ered
47.5 million tons 1/
40

30

Old Scrap Consumed in U.S.

35.7million tons
20

10

0
59 62 65 68 71 74 77 80 83 86 89 92 95 98 01 04 07 10
19 19 19 19 19 19 19 19 19 19 19 19 19 19 20 20 20 20
Old Scrap Old+Net Exports

Source: JJolly, Jan. 2013

1/ Copper in net scrap exports are added to old scrap consumption.

39
The decrease in RIR shown between 1993 and 2002 whose feasibility of economic recovery is not
in Table 6B and rate of recovery (ROR) can be established.
explained by at least two factors that affected the U.S.
semi fabricating industry and scrap recovery trends Using this formula (called the McKelvey formula)
over this period. One was the increased availability assumes (1) the Bureau of Mines (now USGS)
and use of primary copper in the production of semi estimate for world reserves are the correct order of
fabricates over much of this period. The increase in magnitude, (2) that McKelvey’s relation of reserves to
primary copper consumption was partially attributable crustal abundance is valid, and (3) that trace elements
to an increase in wire rod production (which are log-normally distributed in the earth’s crust. Using
consumes less scrap) vis-à-vis a coincidental decline the world copper reserves reported then by the
in secondary smelting of scrap for use in brass mill Bureau of Mines, Erickson estimated that for 1970 the
production (which customarily uses more scrap). reported reserves of 200 million tons resulted in a
Secondary smelting and refining of scrap for use in recoverable resource potential of 2.12 billion tons of
the U.S. industry has been impacted by plant closures copper. This contrasts with reported world copper
and capacity loss over the past ten years (see Table reserves (2005 Mineral Commodity Summary, USGS)
17B). In addition, primary copper was to become for 2004 of 470 million metric tons of copper (and, a
more available at a more reasonable price as copper reserve-base of 940 million tons). Using this latest
supplies were in world surplus over much of the data with the McKelvey formula would yield about 5
1990’s. The second factor is the reduction in amount billion tons of potential recoverable copper, more than
of new scrap produced by the fabricators as double the amount estimated for 1970. Using this
processes became more efficient and streamlined. minimal resource calculation to compare with the
Because of the surplus supplies and consequent accumulated world consumption figure of 282 million
depressed copper prices, less old scrap also was tons (2004) can give us a minimal percent of copper
returned to the market, as might be expected. This already used from an estimated world resource. The
resulted in less scrap being made available to the estimated world consumption of 282 million tons is
U.S. industry for consumption, or for export, over the only about 6% of the minimal estimated world
1993-2001 period. If the years prior to 1993 can be resource. A more recent (1998) assessment of U.S.
presumed to be considered more normal, it would copper resources indicated 550 million tons in
appear that a more normal rate for the recycling identified and undiscovered resources in the United
recovery ratio (ROR) in the United States was in States, more than double the previous estimate
excess of 63%. (USGS Circular 1178, 2000).

During 2005, owing to near term copper market A word of caution -- It is obvious that these
shortages, several articles appeared in the press reserve/resource numbers are very fluid and change
regarding a possible high percentage of copper with time. One must read and understand the
already mined as compared with an estimated total definitions for reserves, reserve-base and resources
copper available in the earth’s crust. Since the Paley to understand the reasons underlying the near
Commission Report of 1950, there have been many doubling of reserves between 1970 and 2004.
such discussions and reports attempting to resolve Absolute amounts are impossible to quantify, thus a
the many issues involved with determining the amount definitive statement about the percentage copper
of copper resources available in the world. One such already used in the world, compared with that possibly
report worth remembering is that appearing in U. S. available is at best, wildly speculative. Statements
Geological Survey Professional Paper 820, pp 21-25. made about running out of the potential for copper ore
This 1973 article, entitled “Crustal Abundance of are irresponsible and generally are made for various
Elements, and Mineral Reserves and Resources”, by political and notoriety reasons.
R. L. Erickson, proposes a methodology for estimating
the recoverable amounts of several metals in the In testimony before the Committee on Resources
earth’s crust. The potential recoverable resource for Subcommittee on Energy and Mineral Resources in
most elements should approach R=2.45AX 10 6 , the U.S. House of Representatives (May18, 2006), a
where A is the abundance expressed in grams per spokesman for the U.S. Geological Survey reported
metric ton, or parts per million and R is the resource that a current study estimated that about 1.1 billion
expressed in metric tons. Those metals whose tons of copper will be needed between 2000 and 2020
reserves most closely approach the calculated at current rates of consumption. This will necessitate
potential recoverable resource are the metals that additional producing reserves equivalent to three
have been most diligently sought, such as copper. times the amount of copper as is contained in the 5
The formula calculates the minimum total resource largest known deposits. Although some of this
available, largely because it relates to currently material exists in discovered deposits, much will need
recoverable resources and does not include resources to come from yet undiscovered deposits. The need for
active exploration and mine development continues.

40
 can be used to further ensure that metallic choppings
CHAPTER 3: 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
difficult.
Scrap preparation
In recent years, owing to the vast labor and copper
All scrap used must be prepared and analyzed prior price differences between China and India with North
to processing to alter its shape and size and/or its American or Western Europe scrap processors, some
purity. This can sometimes add significant cost to its U.S. shredder operators were forced to rethink their
use. Scrap preparation may be done by manual, downstream systems to determine whether or not it
mechanical, pyrometallurgical or hydrometallurgical was worth the operating costs to purify metals to such
methods. Manual separation and cutting of large an extent. Many scrap processors were accustomed
pieces of scrapped items is very necessary, as is an to using automation to meet strict chemistry
accurate analysis of the material. Large, solid items requirements for copper shipments, but exports to
are reduced in size by diamond saws, shearing China and the Far East changed this with the
machines, pneumatic cutters, or manually by a willingness of foreign importers to buy mixed or
sledgehammer. Mechanical methods include sorting, crudely sorted loads of metal. It has steered some
stripping, shredding, and magnetic and air separation. recyclers to do a lot less sorting of loose brass,
Because scrap is a bulky material, the customary copper and aluminum scrap with overseas customers
practice is to bale light scrap and cut heavy scrap to able to do this sorting much more affordably.
size so that it can be handled. The scrap may be
further compressed by hydraulic press into briquettes, In the past decade, as prices for nonferrous metals
bales, bundles or hockey pucks. Brittle, springy have climbed to new highs, methods for better
turnings are crushed in hammer mills or ball mills to extractions of these metals from auto shredding
reduce bulk for easier handling. Slags, drosses, products have been developed and improved Optical
skimmings, foundry ashes, spills, and sweepings may sorting technology has evolved as an improved
be ground to liberate prills or other metallics from the technique to separate metals. In addition to the
nonmetallics so that metallic fraction can be recovered magnets, eddy currents, X-ray Transmission (XRT)
by gravity separation or other physical means. They units, and inductive sorters, optical systems that work
may also be set aside in special areas to be drained in near-infrared (NIR) wavelengths can prove valuable
of oil before further processing. Pyrometallurgical to separate insulated copper wire from the material
preparation may include sweating, burning insulation flow. A camera sorter that uses a charge-coupled
from copper wire (not recommended, and may be device (CCD) can differentiate between different
banned) and kiln drying to volatilize oil and other colored metals. It can be used, for example, to
organic compounds. Cartridge shell scrap may also separate the copper from aluminum. It can also be
be heated in a furnace to pop the live shells. sued to detect shape of pieces, so wires can be
separated from mixed metal fractions. Such plants in
An important copper recycling material is cable scrap. the future will allow recyclers to upgrade the value of
At one time, burning of cable to remove the plastic the nonferrous metals, converting them into higher-
parts was acceptable practice, but this is no longer valued products (Recycling Today,Nov 2011, p. 55-
always possible or desirable. Thus, mechanical 56). From heavy metals recovered, it is possible to
dismantling of the cables is common practice through select the mixed red metal fraction of copper and
cutting, granulating and use of various metal yellow brass, and further refine it to a dedicated
separation techniques to separate the plastics and copper and a dedicated yellow brass.
fluff from the metal. Most wire is chopped into pieces
smaller than 0.5 inch to assure liberation of wire from Over much of the past ten years, especially during the
insulation so that air tabling can then make a market turmoil of 2008-2009, as well as earlier in the
separation. Another mechanical device strips decade, U.S. scrap recyclers of wire and cable were
insulation from long lengths of cable. Over time, wire worried about their future. Brokers representing
choppers have been able to upgrade insulated wire to consumers in China were making generous offers and
No. 1 grade instead of No. 2, which was generated by getting access to scrap that had previously gone to
burning. the choppers. giving stiff competition for feedstock.
Though it was only temporarily, trading patterns
After cable material travels through shredders and shifted somewhat in 2004 when customs, trade and
granulators, a variety of equipment – gravity or air environmental regulations in China combined to slow
density tables, washing systems, fluidized bed units – down the buying pace of Chinese brokers. U.S. wire

41
processors had an opportunity at this time to re- metal recovery. Pelletization of the zinc dusts reduces
establish trading ties with customers (Recycling the volume for shipping and facilitates handling. Some
Today, October 2004). The renewed business allowed companies ship up to 2,000 pounds of zinc dusts in
some processors in the United States to begin large plastic bags (Supersaks).
upgrading their systems. The objective was to remain
competitive while recovering as much metal as When circuit boards used by the printed wire board
possible, but keeping their costs down. Recent gains industry are manufactured, the bonded copper foil that
in volume allowed upgrade to larger shredding units is applied to the fiberglass sheets is trimmed by
and the conveying systems to match. The cost of shearing off the rough edges. This copper-clad trim is
blade replacement was also closely monitored. shipped to some hydrometallurgical firms for
processing to produce copper chemicals. During the
In 2002, it was reported that lower grades of wire production of printed wire circuit boards, a cupric
increasingly had been heading overseas for ammonium chloride etchant is used for removal of
processing (Recycling Today, Feb. 2002). This may copper metal from the unprotected parts of the
partially account for the increasing gap between what boards. Copper increases in the etching solution as
some countries report as exported (see Table 3) what the process proceeds. The spent etchant is shipped to
other countries , particularly China, report as imported a hydrometallurgical processor for removal of the
(see Table 4). There is obviously a difference in copper and regeneration of the etchant. Another
reporting scrap values, which seems to be worsening etchant is cupric chloride. Spent cupric chloride
every year. Data reported by the USITC since 2006 etchant contains about 1.2 pounds of copper per
show increased Number 2 scrap in U.S. exports (see gallon. This metal is also recovered, but the etchant is
Table 8A). No. 2 scrap comprised more than 77% of converted to ammonia chloride, which is returned to
unalloyed copper scrap exported in 2012. Exports of the circuit board industry.
low-grade copper ash and residues also increased
from 8,340 tons in 2001 to 62,150 tons in 2007 and Some large U.S. companies have shredders that can
38,000 tons in 2011 (see Table 9). Total alloy and process electronic materials to allow for metal
mixed scrap comprise the largest share (60%) of total recovery. Canada is a large export market for circuit
scrap exports in 2012 China was the destination for boards that can be handled by shredder and smelter.
75% of the U.S. scrap exported in 2011 (USGS 2011 According to Recycling Today (Feb. 2002), a
MYB, Table 18). Hong Kong, Canada, Korea, Midwestern recycler dismantles computers and other
Mexico, Spain, Belgium and Taiwan were also electronic products by hand and sends the circuit
significant importers of U.S. copper and copper alloy boards to smelters (presumably in Canada), which
scrap in 2010 and 2011. have associated shredders. Because the company
charges a per-pound fee to recycle electronics, the
While copper and aluminum have resale value to dismantling is financially viable. Many of the
smelters, the plastic coating is often disposed, or computers handled are reused instead of dismantled.
burned away. In developing countries, plastics are There was a strong demand for the reuse of Pentium
disposed of not only through landfilling but also by 133s and above, but anything less is likely being
open burning of the coated wire Recycling Today purchased by dealers who send the computers to third
estimates that some 700 controlled-atmosphere world nations, such as China. Beryllium copper clips
furnaces have been sold worldwide to scrap recyclers gleaned from these electronics are sorted and sent
who use them to burn off plastic coating. Scrubbers back to beryllium copper producers in Ohio and
are used with these furnaces to remove the Pennsylvania. Handling these materials must be done
hydrochloric acid generated when burning PVC. Open carefully, since any hazardous materials from
burning offers no 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 The Institute of Scrap Recycling Industries released a
more than 10% copper. The slag is ground and comprehensive survey of U.S. electronics recycling
combined with water and flotation chemicals. The companies at the 2011 E-Scrap Conference. One
additives help the copper to float for removal and noteworthy find by the survey, which was conducted
concentration and to prepare it for further processing. by International Data Corporation, determined that
182 US organizations reported that most end-of-life
In 1974, H. Fukubayashi (USBM RI 7880, 1974) electronics are being processed in the United States
estimated that flue dust collected from secondary and not dumped overseas. Seventy percent of
brass furnaces averaged about 2 tons per day per collected e-scrap is processed in the United States
operating brass furnace. The material is ordinarily too and sold as commodity-grade materials including
light and fluffy for easy handling and, thus, is shipped copper and precious metals. Some is resold as
in containers, such as barrels, to the zinc smelters for functioning equipment and nearly 18% is resold as

42
equipment and components for further repair and automotive radiator, which typically uses 40% scrap,
refurbishment. (Resource Recycling, Nov 2011) mainly for brass in tubes and header plates, the
energy intensity is 20 MWh/t, not the 30 MWh/t of
Some companies recycle copper by newly produced copper.
hydrometallurgical processing of weak or spent
copper plating solutions and sludge generated by Scrap Preparation. Chopping of copper wire requires
wastewater treatment of copper plating operations. about 1.75 million Btu (USBM, IC 8781, 1978) per ton
The product is sent to a smelter for further processing. of prepared scrap; 1.05 million Btu of which represents
process energy, 0.40 million Btu represents pollution
control energy, and 0.3 million Btu is for space heating.
Laboratory Testing By comparison, incineration of the covered wire
requires 1.67 million Btu, most of which is consumed in
Several standard methods of testing scrap materials, the afterburner. If the insulation contains PVC, a
ingots and other alloy products are used. Methods serious air pollution problem arises, requiring the use of
such as chemical analysis, optical emission wet scrubbers and the treatment of the effluent. The
spectroscopy, x-ray fluorescence, atomic absorption electric energy required for compressing low-density
analysis, inductively coupled plasma-emission scrap into balers is less than 0.05 million Btu per ton.
spectrometry analysis and various types of For briquetting, the electric energy requirement is on
mechanical testing are used. Details for conducting the order of 0.10 million Btu per ton.
wet chemical analysis on copper-based alloys are
given in several ASTM standards (E 478, E 54, E 75, Melting Scrap. Reverb melting of No. 1 copper scrap
E 88). The wet chemical methods are slow and make requires about 3.81 million Btu per ton of refined
it difficult to obtain results for production heats until copper shapes poured, such as billets and cakes. Of
well after the metal has been cast, limiting their value this, about 95% is process energy; the remainder
as a process control tool. More commonly, chemical represents pollution control and space heating energy.
methods are used for analyzing the composition of Recycling of No. 2 scrap requires process energy of
raw materials (ingot and scrap) before being melted. 15.71 million Btu per ton of poured copper wire bar.
The mechanical tests usually associated with copper- Air pollution control energy accounts for 0.21 million
based foundry alloys are those for hardness, tensile Btu per ton of wire bar, and space heating accounts
and impact-strength properties, following various for an additional 1.35 million Btu per ton. The total of
ASTM standards. Radiographic inspection of metallic these components amounts to 17.27 million Btu per
objects is a means of observing internal defects ton of copper wire bar produced from No. 2 scrap.
nondestructively by using either x-rays or gamma
rays. Process energy required for recycling brass and
bronze scrap to ingot (85:5:5:5 red brass) is about
Occasionally, a radioactive check must be made on 5.86 million Btu per ton of alloy produced. Air pollution
materials received for processing. Copper scrap from control energy accounts for 0.91 million Btu, and
atomic power plants is particularly suspect. While the space heating accounts for 0.32 million Btu, making a
radioactive elements can be separated from the total energy requirement of 7.09 million Btu per ton of
copper metal produced during smelting the material, red brass alloy produced. The energy analyses for
the slags may become contaminated and radioactive. other alloys are not significantly different.

Process energy for processing low-grade, copper-

Energy Use bearing scrap (25% to 35% copper) in a reverberatory
or cupola requires 39.70 million Btu per ton of product.
Recycling provides benefits such as energy savings. Total energy required is 42.42 million Btu per ton of
Of the commonly used metals, copper has one of the product, including 1.37 million Btu for pollution control
lowest energy intensities for production. The energy energy and 1.35 million Btu for space heating (USBM,
intensity for recycling of copper varies by the purity of 1978).
the scrap. Clean scrap, which requires only remelting,
requires only about 1 MWh/t. Scrap that requires
electrolytic refining requires about 6 MWh/t, and that Scrap Melting and Processing
which must be purified by re-smelting requires about
14 MWh/t. Most purchased new scrap is simply melted at ingot
makers and brass mills. Copper from direct melt scrap
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

43
pure copper product. Fire refining in a reverberatory or Melt Control. The term melt control refers to the
other furnace may be sufficient for the better grades. control for furnace and atmosphere conditions during
processing of molten metal. Variables affecting melt
The fire-refining process uses oxidation, fluxing and quality include the following: (1) Furnace selection; (2)
reduction to produce refined ingot, wire bar, slab or Fluidity (Higher pouring temperatures make chemistry
billet. For higher grades of refined cathode, however, and gas control more difficult.); (3) Mold materials (All
the poorer grades of scrap must be first smelted with materials can produce gas, and mold gas coupled
various fluxes, poled to remove oxygen, and then cast with gas derived from melting can result in “gassy
into anode form for further processing to cathode in an castings”); (4) Gating (Improper gating can result in
electrolytic refinery. By-products, such as tin and gas pickup and porous castings.); (5) Solidification
precious metals, may be retrieved during the and shrinkage; and, (6) Mechanical properties (Input
preliminary procedures of smelting or, during refining, materials are commercial-purity raw materials, scrap,
from tank house sludges. Other impurities, such as secondary ingot, returns, and late additions. How
iron, lead, arsenic and antimony may be removed much of each is used is dependent upon availability,
from the slag by fluxing. Reverberatory or electric cost and the casting quality required). Some
rotary melting furnaces are used for casting various companies use a computerized system to determine
copper forms, such as slabs, cakes, billets or ingots. the heat characteristics, cost and most efficient
Asarco shaft furnaces may be used with holding method of mixing the melt, including the detailed
furnaces, in conjunction with continuous casting procedure to be followed in forming it. This helps to
systems. simplify the procedure to be followed for a particular
alloy. Often, three or more scrap types are required
Processing complex copper-containing materials, for a given melt.
such as drosses, flue dust, catalysts, collector dust,
slimes from electroplating wastewater, and metal-rich Commercial-purity raw materials are seldom justified
slags from converter and furnace processes requires on cost, except possibly for new alloy development.
versatile production processes. Low-grade, copper- Other pure metal scrap, such as zinc strip, may also
bearing scrap, such as copper-containing skimmings, be used for adding metal to the melt. Some elements,
grindings, ashes, iron-containing brasses and copper such as silicon in the silicon bronzes and iron in the
residues are usually smelted in a cupola or blast aluminum bronzes, do not readily go into solution in
furnace to produce black copper. Black copper is then copper and, so, are often purchased as already
converted to blister copper in a converter and, then, is alloyed ingot. These additive alloys are called master
fire-refined or electro refined, much as in the primary alloys. Master alloys contain 10% to 15% of the
copper industry. desired metal required. Most foundries to do not
compound their own alloys from raw materials. The
Most metal processing plants have built-in water practice of using an all-scrap charge creates the risk
recirculation systems and pickling solutions in which of possible pickup of detrimental elements. On the
some of the metal content is recaptured and reused. other hand, scrap, such as pure copper bus bar, wire
Many of these wastes also must be treated for metal or piping, provides an excellent charge of known
recovery. In general, a combination of various characteristics. Another example of scrap use is the
hydrometallurgical techniques such as precipitation, melting of soldered brass automotive radiator cores
cementation, ion exchange, solvent extraction, for plumbing alloy castings, because of the known
reverse osmosis, gaseous reduction and electrolysis lead content.
are used. Cementation has been successfully
employed to recover copper from waste effluents. Drosses and Dross Formation. The most common
Solvent extraction and ion exchange are highly causes of melt losses are dross formation due to
selective methods for separation of copper from other reaction with the atmosphere, refractory material, or
common metals in solution. Mechanical and thermal ladle material, and losses owing to vaporization of
dismantling, and more recently, leaching and solvent low-boiling point elements. Even if secondary ingot
extraction and electrowinning procedures have proved charges are well within a chemical specification range,
effective in treatment of certain types of electronic melt losses may result in scrap castings. Much of the
scrap and copper-coated steel wire. Electrowinning dross in copper-base alloy melts (Casting Copper-
recovery is also used for waste processing fluids and Base Alloys, 1984) is due to reaction between the
sludges that contain copper and other metals. A low- metal and the atmosphere, since it is usually not
grade copper cathode, as well as copper chemicals possible to exclude the atmosphere. Several
such as copper sulfates, oxides and hydroxides, techniques may be used to minimize dross formation.
copper precipitates and by-product metals can be These include the use of lower temperatures, shorter
produced through this method. furnace time, crucibles or refractories that are inert to
the melt, and melt covers or fluxes. Lower
temperatures result in less dross through lower

44
chemical reaction rates. Clay graphite crucibles is used for deoxidizing. In some cases, the flux alloy is
provide carbon in the crucible that will react with the added so that the excess phosphorus will alloy with
atmosphere, resulting in less dross. Melt covers, such the melt as one of the desired constituents. In this
as charcoal, carbon and fluxes, show mixed results case, the alloy is used as a deoxidizer and a
but also can be effective in reducing the amount of hardener. There are many other fluxing alloys such as
dross formed. One company reported an 80% the binaries of silicon, manganese, magnesium,
reduction in dross and ash formation through the use lithium and cadmium.
of synthetic graphite instead of charcoal as a melt
cover. Oxidizing melt covers (copper oxide, silicate-borate
mixtures) can be used to remove hydrogen, or
Melt Covers (Fluxes). Fluxing is an essential part of maintain it at low levels, and to consolidate drosses
both melting and refining. The basic functions of and oxides for ease of removal. Neutral melt covers
fluxes are essentially the same, whether used in (glass, dry silica sand) form a mechanical barrier
reverberatory, rotary or crucible furnaces. Two between the melt and the furnace atmosphere. This
general types of fluxes used for melting and refining can reduce exposure to hydrogen sources, but may
scrap copper are: (1) Nonmetallic fluxes and (2) also prevent oxygen absorption; it is generally not
Fluxing alloys. Nonmetallic fluxes may be solid, liquid, reliable for gas control, but it is advantageous for
gaseous or mixtures of these. Some are used for dross removal and reduction of vaporization losses.
protecting the surface of a melt from the atmosphere,
while others refine by mechanical or chemical Reducing melt covers (charcoal, graphite) prevent
reaction. excessive oxidation losses but may be a source of
hydrogen, if they contain moisture or hydrocarbon
Nonmetallic fluxes include materials such as sodium additives. If used in excess, they may prohibit oxygen
chloride, charcoal, borax, anhydrous rasorite, absorption from the melt atmosphere, thereby
slacklime, glass, nitrogen, oxygen and various allowing hydrogen pickup. Reducing melt covers are
combinations of these. Sodium chloride may be used useful in retaining a low oxygen level in the metal after
as a cover and as a fluid medium for separating deoxidization and prior to pouring.
metallic and nonmetallic materials in heterogeneous
melts. Charcoal covers are used to add heat to the Fluxes or slag covers are generally unnecessary
surface and provide a reducing atmosphere. Borax, when melting copper and beryllium copper alloys. A
slacklime and glass are added in various layer of dry charcoal or granular graphite may be used
combinations to protect the metal surface and reduce to cover molten copper. In melting chromium copper,
volatilization of the melt. Anhydrous rasorite is a a flux cover of lead-free glass or liquid salt is
sodium borate flux used in the secondary copper recommended to minimize oxidation of chromium.
industry. This flux has a great affinity for metal oxides
and siliceous materials and is used primarily to Fluxing materials used in a typical blast furnace
scavenge oxides and to provide a protective cover for include limestone, mill scale, and metallic iron. The
molten scrap brass and bronze. Borax is also used to resulting slag from a 60- to 70- ton-per-day blast
aid the release of ingots from their molds. Caustic furnace (Spendlove, 1961) with charge materials
soda has been used for the removal of iron and containing 10–11% coke, will have the following
aluminum from some alloys. Gaseous fluxes are approximate composition: FeO (29%), CaO (19%),
usually introduced into the melt through a pipe SiO2 (39%), Zn (10%), Cu (0.8%) and Sn (0.7%).
inserted below the surface. Small bubbles of inert gas
adhere to particles providing buoyancy, which raises Use of Deoxidizers. Phosphor copper is often used
them to the surface where they can be removed with in deoxidization of copper and copper alloy melts such
the slag. as in making copper tube and copper-tin-lead-zinc
alloys (red brasses and tin bronzes). The principal
Metallic fluxes are either pure metals or alloys that cause of high residual phosphorus is over-
can be introduced to the melt to produce a refining deoxidization. This usually occurs for one of two
action. A metal fluxing agent used for copper-base reasons: (1) Porosity problems are misjudged to be
alloys would also be alloyed with copper as a base the result of insufficient deoxidization, or (2) Extra
metal. Fluxing alloys are usually classified according phosphorus is added to impart greater fluidity to the
to their functions. They are known variously as metal to avoid misruns in thin castings, or when
deoxidizers, degasifiers, densifiers, stabilizers and pouring cold metal. Over-deoxidization will result in
fluidizers. Many provide two or more of these gassy castings and will negate efforts to maintain low
functions simultaneously. Some melters may use the hydrogen levels during melting. Because beryllium
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

45
pure copper. In forming high-conductivity copper, a burning generates large amounts of particulate matter,
high oxygen content is induced to the melt to limit the primarily composed of partially combusted organic
amount of hydrogen and to oxidize impurities that may compounds. Direct-flame incinerators, called
be deleterious to conductivity. The melt is then afterburners, can effectively control these emissions.
deoxidized using calcium boride or one of the various An efficiency of 90% or more can be achieved if the
deoxidants available commercially. afterburner combustion temperatures are maintained
above 1000 C (1800 F). If the insulation contains
Cut cathode squares (an alternative primary raw chlorinated organics, such as polyvinyl chloride,
material) contain no oxygen; hence, they may contain hydrogen chloride gas will be generated. Hydrogen
considerable hydrogen, and strong oxidation will be chloride is not controlled by the afterburner and is
needed to remove it. In-process scrap should contain emitted to the atmosphere. In eliminating the burning
neither oxygen nor hydrogen but may contain residual of insulated wire, however, a by-product called fluff is
deoxidants. generated. The industry has been working in
conjunction with firms such as Goodyear Rubber to
Vapor Losses. The techniques used for dross find new uses for this material. Generally, however, it
minimization will also reduce vapor losses. The most is baled and sent to a hazardous materials dump
notable element loss in molten copper (brass) alloys because of its lead content, which was used in
takes place with zinc, which is usually replaced in the plastics to prevent exposure breakdown while in use.
melt just prior to pouring. Elements such as lead and
beryllium may also be associated in the processing of The EPA reported emission factor averages and
some copper alloys. ranges for six different types of furnaces are shown in
Table 19, the data for which was derived from
Particulate Matter and Fugitive Emissions. unpublished documents of the New Jersey
Secondary smelting and melting processes release Department of Environmental Protection; New York
some particulate matter into the air stream used to Department of Air Resources; Wayne County,
oxidize undesirable elements in scrap. Since scrap Michigan, Department of Health; the State of Ohio
does not contain considerable sulfur, arsenic or other EPA, the City of Chicago Department of
volatile elemental combinations found in natural ore Environmental Control; the City of Cleveland
minerals, these are not of great concern here. The Department of Public Health and Welfare; and the
principal materials of concern are those derived from South Coast Air Quality Management District in Los
burning plastic coating materials and electronic Angeles, California.
boards, when a smelting technique is used for these
materials. New hydrometallurgical procedures have
been developed, however, that have been shown to Furnaces
be efficient in removing the precious metals, copper
and other metals from these materials. No fugitive air The kind of raw material that can be used depends
emissions are involved. Another group of elements of upon the furnace in use at a plant. Fire refining and
concern is that of more volatile metals partially smelting require large furnaces or cupolas that are
released during the melting of some copper alloys. distinctly different from that used for direct melt of
These include zinc, mercury, lead and cadmium. scrap. Few ingot makers or brass mills and no
Numerous mechanisms have been developed to keep foundries maintain furnaces that are sufficient for
these emissions to a minimum as well as to capture large-scale fire refining or smelting. These types of
most of the emitted metals through the use of furnaces generally are left to those firms that
emissions scrubbing systems. Both wet scrubbing and specialize in secondary smelting and refining. The
electrostatic precipitators are used. Particulate stationary reverberatory is the most practicable
emissions associated with metal processing can be furnace for large tonnage, but the rotary furnace is
collected in mechanisms called bag houses. Products more flexible. Tilting and stationary crucible furnaces,
recovered from baghouse dusts are generally either gas or electric, are used for making small melts
valuable materials that can be sold for further of special alloys. Electric induction furnaces are
processing or for direct use in certain applications. popular at ingot plants and foundries where special
However, because these materials sometimes contain alloys are made. These furnaces also are used for
certain metals currently classified as hazardous air melting scrap and other materials in casting billet and
pollutants (HAPs), as defined in Title III of the 1990 other shapes.
Clean Air Act Amendments, they are shipped and sold
as hazardous materials. No. 1 and No. 2 scrap can be melted in a reverb or
rotary furnace for fire refining, similar to the process
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

46
carried out until the oxygen content is around 0.2%. fuel-to-air mixture, the atmosphere is kept slightly
The molten copper is then cast on a molding wheel, reducing. Fuels include natural gas, propane, butane
either into anodes for further electrolytic refining or and naphtha. Energy consumption is 1 million Kcal
into wire bar or ingot for use by foundries and brass per ton of cathode.
mills. When anodes are refined, the tank house
sludges are sources of valuable by-products such as Crucible Furnaces. A fairly large tonnage of
precious metals. secondary copper products is produced in crucible
furnaces. These furnaces are fuel-fired with natural
To process low-grade copper scrap, secondary gas, fuel oil, propane or combinations of these. These
smelters commonly use a combination of cupola, fuels are all hydrocarbons. As a result, their
blast, reverberatory or rotary furnaces that are either combustion causes the formation of large quantities of
gas or electrically fired. A flux is commonly added to water vapor. The water vaporizes if part of the visible
retrieve impurities in the earlier stages of the process, flame comes into contact with the molten metal before
and a slag product is also produced in addition to the it is exhausted from the furnace. Crucible furnaces are
high-copper melt. The upgraded copper melt is used for melting clean, well-segregated scrap –
charged to a converter where the product is oxidized mostly in foundries. Nonmetallic fluxes are used for a
to remove unwanted gases and the purity is increased protective covering, but alloy fluxes may be added as
to around 90%. It’s then moved to a fire-refining a refining agent and as a means of introducing some
furnace where the product is further upgraded to constituents into the melt.
around 99% copper and is poled with either gas or
wood to remove the residual oxygen. The most common cause of porous copper-alloy
castings is the reaction of the water vapor with the
Arc Furnaces. Once popular, arc furnaces are not molten metal allowing dangerously high amounts of
used as much in copper-alloy ingot makers and hydrogen to be formed and dissolved by the melt. Use
foundries today. Whether direct-arc, indirect-arc or of a cover material on the surface of the molten bath
submerged-arc, these furnaces melt within a closed has been used to avoid or prevent hydrogen
chamber. The material is heated either directly by an contamination in fuel-fired furnaces. The use of
electric arc between an electrode and the work or glassy, slag-like covers can be relatively effective in
indirectly by an arc between two electrodes adjacent protecting the melt, but there are disadvantages. Such
to the material (ASM Metals Handbook). The intense covers can prevent oxygen in the furnace from
heat of the arc causes combustion of the graphite reacting with the bath. The British, reportedly, have
electrodes to occur by reaction with any oxygen been known to add oxidizing materials, such as
present in the furnace atmosphere. The remaining cuprous oxide, to the slag cover to overcome this
atmosphere is nitrogen, carbon monoxide and any disadvantage. At best, however, covers can be a
residual moisture from incoming air. Suppressing potential source of inclusions in castings, and their
hydrogen absorption by excess air has the use shortens the life of furnace refractories and
disadvantage of greatly increasing the rate of reduces the thermal efficiency during melting.
electrode consumption. Sealing off the tap hole with
refractory cement also minimizes the flow of air into Scrap is usually melted in crucibles by the puddling
the furnace, but it depends upon keeping atmospheric method – melting enough scrap to make a liquid
moisture out. Flushing the heat with dry nitrogen or an puddle, then forcing new scrap below the surface to
inert gas can reduce hydrogen absorption, if become part of the molten body. Crucible furnaces
necessary. The submerged-electric-arc furnace is may be either stationary or tilting, the latter being the
used for extracting metal components from reduced most preferred. A ceramic-type of material (dry-
scrap pellets by Inmetco Corp., according to its Web vibration, low-moisture cast able lining) is usually used
site, where it claimed to be the only secondary to line the furnace in a manner not unlike molding
submerged-arc smelting furnace in North America cement.
dedicated to the high-temperature metal recovery of
nickel, chromium and iron. Blast Furnace, Cupola. The function of a blast
furnace is the reduction of copper compounds and the
ASARCO Furnaces. Named after the American formation of copper matte and slag. The blast furnace
Smelting and Refining Company, these furnaces are is used in secondary smelters for smelting low-grade
commonly used for melting pure copper cathodes and copper and brass scraps, refinery slags, drosses and
clean scrap. The product is tough-pitch copper, which skimmings. When used primarily for melting scrap,
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

47
bottom of the shaft. The upper section of the shaft is copper producers currently use flash-furnace
cylindrical, but the lower section (the bosh) is an technology for smelting ores and concentrates. Flash
inverted, truncated, tapering cone. A crucible is placed furnaces, operating with the exothermic heat of sulfur
below the bosh to collect molten metal and slag oxidation, do not require much scrap except for
produced in the smelting zone above. Refractories cooling the melt. This has resulted in a significant
used in the furnace are usually fire-clay brick from top reduction of low-grade copper scrap consumption by
to bottom. The crucible is lined with magnesite or the primary producers.
chrome brick.
Converters. Scrap may also be added to a primary
The scrap is heated as it descends through hot rising copper converter as a convenient way to keep the
gases, becoming liquid when it reaches the smelting melt from exceeding the proper temperature. These
zone. Brass and copper may actually melt above the vessels are used for converting primary copper matte,
normal smelting zone. Limestone, silica and iron oxide an impure mixture of iron and copper sulfides, into
fuse in the smelting zone and form a molten slag, blister copper by oxidizing the sulfides. The sulfur
which mixes with the metals in the gas turbulence. dioxide gas is expelled with other furnace gases, and
The gases rising through the shaft are composed of the iron oxide combines with a siliceous flux to form
CO, CO2 and nitrogen. The amount of carbon dioxide an iron-silicate slag, which is poured off. A converting
increases at higher elevations in the shaft; the coke- vessel is also used for making blister from black
to-air ratio is adjusted to provide a reducing copper derived from scrap materials, as described
atmosphere. Oxides of the base metals either dissolve above.
in the slag or fume off; many are reduced and
dissolved in the copper. The black-copper product of Rotary Furnaces. Top-blown, rotary converters (e.g.
the blast furnace may contain zinc, lead, tin, bismuth, Kaldo or TBRC furnaces) are sometimes used to
antimony, iron, silver, nickel or other metals contained smelt and refine copper-bearing materials. These
in the scrap. Many of these are later fumed off and furnaces are more flexible than reverbs, but the
recovered as baghouse dust. capacities are limited in size to about 50 short tons
per day of nonferrous metals. They can be operated in
Both slag and metal are usually tapped through a batch or semi-continuous modes. Various feed
launder into a reverberatory where they are held in a materials can be used, such as primary and
quiescent state to allow more complete separation of secondary base metals and anode slimes. Fine feed
metal and slag. The metal product produced in the materials can be fed directly into the furnace without
blast furnace will vary widely depending upon the any pre-treatment, such as briquetting or screening.
materials charged. The range of composition will be The barrel rotation ensures good mixing of flux and
75% to 88% copper, 1.5% tin, 1.5% lead, 0.1% to scrap. The thermal efficiency is good owing to direct
0.7% antimony, 0.5% to 1.5% iron, 4% to 10% zinc, heating of the barrel walls by the burners, followed by
and 0.5% to 1.25% sulfur. The calcium-iron-silica slag direct conduction of the hot refractory wall to the
may also contain up to 1.5% copper. charge as it rotates. Some believe that it has an
advantage over stationary furnaces for melting loose
Reverberatory Furnaces. A reverberatory furnace is or bailed light scrap. The rotary furnace is a cylindrical
a box-like, refractory-lined structure designed to heat steel shell with insulating material placed inside next
the charge by both conduction and radiation. The to the shell. Magnesite or chrome-magnesite brick is
furnace is usually lined with magnesite, or chrome- used for lining. A cushion of grain magnesite usually
magnesite bricks, fused magnesite bottoms, and backs the brick lining. Linings may last 100 or more
suspended magnesite brick roofs. Secondary smelter heats, and the capacity of the furnace may increase
reverberatories may be as large as 100 tons per day owing to the erosion of the lining by abrasion and
or more. Charge materials must contain a minimum of reaction with the slag. Heat losses also increase
40% copper in order to prevent excess slag proportionately. Flux comprises equal amounts of
accumulation, which reacts with the refractories and anhydrous soda ash and anhydrous borax forming
shortens the furnace lining life. Scrap is charged at about 1-1/3% of the charge in melting 85-5-5-5 ingot
regular intervals until the furnace is filled. Melting is (Spendlove, 1961). After melting of the charge, the
more efficient, if light scrap is densified by bailing or metal and dross are tapped off separately. A Kaldo
briquetting. Oxidation and volatilization losses are furnace can meet stringent environmental standards
usually kept to a minimum by rapid melting in a as it produces very low metal content, inert slags. The
slightly oxidizing atmosphere with a fairly fluid slag furnace is compact and can be completely enclosed to
cover. A few of these furnaces are still in operation as prevent any stray emissions.
fire-refining operations associated with copper tube
mills in the United States. The reverberatory furnace Low-frequency Induction Furnaces. Brass mills
used for processing primary copper and scrap at may use low-frequency induction furnaces to melt
primary copper operations has disappeared. Primary copper, copper-alloy scrap, runaround (home) scrap,

48
and significant amounts of primary copper and
alloying elements such as slab zinc. Melting rates with
induction furnaces can be high, but capacity is
typically limited to a maximum of 5 metric tons. Energy
costs for melting are usually higher due to the use of
electrical power, but this may be compensated by the
fact that no combustion gases are generated and no
gas handling system may be needed. The heating
equipment is more complex than standard gas
burners. Induction furnaces produce little metal
oxidation and have high metal recovery rates.
However, they require relatively clean scrap, since
contaminants tend to be entrained or entrapped in the
recirculating molten metal pool.

Electric induction furnaces are often used for melting

scrap and other metal materials in casting billet and
other shapes.

Sweating
Scrap as journal bearings, lead-sheathed cable,
radiators and mixed auto shreddings can be sweated
to remove babbitt, lead and solder as valuable by-
products, which would otherwise contaminate a melt.
Both reverberatory and muffle furnaces are used for
this purpose. The simplest furnace for sweating is the
conventional sloping-hearth-fired furnace (Spendlove,
IC 8002, 1961). The charge materials are placed at
the highest point on the hearth. Low-melting
constituents liquefy and flow to the low end of the
hearth and out of the furnace into a collecting pot. The
sweated babbitt, lead or solder may be used to make
white-metal alloys. Small-sized scrap can be sweated
efficiently in a rotary kiln, with scrap charged
continuously at the elevated end of the kiln.

Because some soldered items are difficult to sweat

when the solder remains in folds and seams, even
when melted, other furnaces have been developed to
counteract this problem. One is a reverberatory
furnace with a shaking grate of steel rails about the
size of the furnace floor. The scrap is shaken to
remove the liquid solders from the scrap. The molten
solder falls to the floor of the furnace, where it flows to
a low corner and is collected. Some melters have
used tunnel furnaces where the scrap is carried on
trays or racks through a heated tunnel by an endless
conveyor. Some of the solder melts and falls from the
scrap while inside the furnace tunnel.

49
CHAPTER 4: Convention as hazardous and, thus, not subject to
any export ban.
Environmental Overview
Annex VII defines the countries of the Convention that
can trade in hazardous wastes (which include
valuable metal containing ashes, drosses and
Since the passage of the Clean Air Act of 1970, residues, etc.) The criteria for defining countries in
numerous laws and regulations relating to improving Annex VII are of concern: the current impasse that
human health and the environment have been restricts these countries to those predominantly from
promulgated by Congress and the federal and state the northern industrialized hemisphere does not
agencies that enforce them. This review is not meant reflect the sources for the hazardous wastes nor the
to be a comprehensive review of all of them but, necessity to treat these materials in countries other
rather, a sampling of some of the more significant than where they are generated (BIR Newsletter,
ones as to how they currently affect the way the 2002).
secondary industry does business.
In 2001, the Basel Convention Conference of Parties
With a view to protect the environment by preventing (COP5), a Protocol on Liability and Compensation,
the production of waste and by organizing its disposal was adopted for damage resulting from transboundary
or recycling, administrations and legislators worldwide movements of hazardous wastes and their disposal.
have decided to take charge of all aspects of waste (www.basel.int/meetings/cop/cop5/docs/prot-e.pdf) A
management — whether hazardous or not — declaration also was made reaffirming the Convention
including the management of recyclable raw materials and supporting sustainable development. Areas
that the industry recycles, processes and sells. targeted for further study included waste minimization,
Regulators tend not to distinguish between recyclable cleaner technologies, recovery and disposal of wastes
raw materials and waste and, in the process, create as well as waste prevention. The meeting for COP 6
enormous obstacles for the entire reclamation and took place in Geneva in May 2002.
recycling industry. Metals should not be viewed as
wastes but rather as renewable resources that can be In the current decade (2000-2010), the Convention
used again and again in new products, conserving planned on implementation and enforcement of treaty
scarce resources, saving energy and preventing commitments. The other area of focus is the
pollution. Recycling should be given priority over minimization of hazardous waste generation. A central
disposal. The failure to look at the interplay of goal of the Basel Convention is Environmentally
markets, commodities and regulations before putting Sound Management (ESM). ESM addresses the issue
into effect new recycling regulations has ended up through an “integrated life-cycle approach.”
being a very costly storage and disposal program. 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
scrap, slags and oxide mill scale were placed in the B controls in exceptional cases. Examples of exceptions
list. The B list of materials is not covered by the Basel for green and amber wastes, respectively, are:
electronic scrap and drained motor vehicle wrecks;

50
and, flammable magnesium scrap and vanadium where a “release” has occurred. Section 107(b)
residues. OECD membership is comprised of 30 provides three possible defenses to liability: an act of
countries including the EU and United States. The God, an act of war, or action by a third party under
major points of “benefit” to the recycling industry certain circumstances.
include the following: (1) A new definition for a mixture
of wastes, specifying it as a waste that results from a To identify PRPs responsible for site contamination,
mixing of two or more different wastes. A single EPA reconstructs the history of operations that
shipment consisting of two or more wastes, where occurred at the site, by conducting an extensive
each waste is separated, is not a mixture of wastes. search through site, state agency and EPA files. Once
(2) Green, as a control procedure, shall be applied to EPA has enough information to identify parties as
mixtures of green wastes for which no individual entry potentially liable for contamination of a site, EPA
exists. On the other hand, where green waste is issues a general notice letter to each PRP, notifying
mixed with more than a minimal amount of amber them of their potential liability.
waste, or a mixture of amber wastes, it will be
subjected to the amber control procedure. 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
site, any person who at the time of disposal of are involved in reclaiming recycled materials. The
hazardous substances owned or operated the EPA estimated the cost to remaining liable parties at
property, or any person who arranged for disposal or current Superfund sites would range between $156
transportation of hazardous substances at a property million and $175 million. According to an ISRI list, 16

51
Superfund sites would be affected by the new (2) EPA determines that the site poses a
legislation. Two of the sites are former brass significant threat to public health; and,
foundries, and another two are former scrap metal
reprocessing sites. (3) EPA anticipates it will be more cost-effective to
use its remedial authority (available only at
Included in the 1999 Superfund liability amendment NPL sites) than to use its emergency removal
were scrap paper, plastic, glass, textiles, rubber, authority to respond to the site.
metal, and spent lead-acid, nickel cadmium and other
batteries, as well as minor amounts of material Resource Conservation and Recovery Act
incident to, or adhering to, the scrap material as a (RCRA)
result of its normal use. Shipping containers with 30
liters to 3,000 liters capacity that had hazardous
RCRA was passed into law in 1976. The goals of the
materials associated were not included.
law are to conserve energy and natural resources,
reduce the amount of waste generated and ensure
Transactions involving scrap metal must demonstrate
that wastes are managed to protect human health and
that the person making the transaction is in
the environment. RCRA gives EPA power to make
compliance with all regulations or standards for
and enforce regulations for managing many kinds of
storage, transport, management or other activities
wastes. RCRA regulations apply to 3 kinds of waste
associated with metal recycling and that the person
management: municipal, solid waste landfills;
did not melt the scrap metal prior to the transaction.
hazardous waste generators and transporters, and
Melting, according to this definition, does not include
treatment, storage and disposal facilities; and
sweating to thermally separate metals. Scrap metal is
underground tanks that store hazardous materials.
defined as bits and pieces of metal parts or metal
pieces held together with bolts or soldering.
Generally, sites that may be cleaned up under RCRA
or certain other laws will not be put on the NPL. By
Hazard Ranking System (HRS). First promulgated
“deferring” the cleanup authority to another program
July 16, 1982 (47 FR 51532), as Appendix A of the
like RCRA prior to placement on the NPL, EPA can
NCP, it was revised December 14, 1990, in response
reserve CERCLA response activity funding for sites
to CERCLA Section 105(c). The HRS is the principal
that are not eligible to be addressed under other
mechanism that EPA uses to place uncontrolled
federal authorities. If a site on the NPL falls under
waste sites on the NPL. It is a numerically based
RCRA authority, it usually will undergo RCRA
screening system derived from the preliminary
corrective action before Superfund remedial activity.
assessment and the site inspection. The sites with the
In some cases, the EPA may delete the site from the
highest scores do not necessarily get the first
NPL. For more information on the interface between
attention. EPA relies on more detailed studies in the
RCRA and CERCLA, see the September 24, 1996,
remedial investigation/feasibility study that typically
EPA memorandum entitled Coordination between
follows listing. Factors are grouped into three
RCRA Corrective Action and Closure and CERCLA
categories: the likelihood that the site poses a
Site Activities.
hazardous substance release into the environment;
the characteristics of the toxicity and waste quantity;
In 2011, EPA proposed a broad newly expanded
and the people or sensitive environments affected by
definition of waste. Published in the Federal Register
the release expected. Four pathways are scored:
on July 22, 2011 EPA proposed to revise certain
ground water migration, surface water migration, soil
exclusions from the definition of solid waste for
exposure (population affected), and air migration
hazardous secondary materials intended for
(population and sensitive environments affected). The
reclamation that would otherwise be regulated under
site score can be high, even if only one pathway score
Subtitle C of the Resource Conservation and
is high. Sites are placed on the NPL using the HRS.
Recovery Act (RCRA). The proposed rule would
The second mechanism for placing sites on the NPL
require all forms of hazardous waste recycling to meet
allows states or territories to designate one top-priority
requirements designed to ensure materials are
site, regardless of score. A third mechanism allows
legitimately recycled and not being disposed of
listing the site if it meets all three of the following
illegally. Of concern to scrap recyclers is the potential
requirements:
breadth of the DSW rule as proposed. Among the list
of 27 North American Industry Classification System
(1) The Agency for Toxic Substances and Disease
(NAICS) sectors designated for the proposals is the
Registry (ATSDR) of the U.S. Public Health
secondary smelting, refining and alloying of
Service has issued a health advisory that
nonferrous metal (331492) sector. The impact of this
recommends removing people from the site;
proposal on the scrap recycling industry seemed to be
totally ignored by the EPA. ISRI estimated the rule

52
change could cost the industry about$1.2 billion Procedure (TCLP). Two objectives were satisfied: (1)
(Recycling Today, Nov. 2011, p. 87). a test to generate replicable results for organics, and
(2) a test that could yield the same results for
Toxicity Characteristic Leaching inorganics as the original EP test. The TLCP began
Procedure (TCLP) with the same assumptions that waste would be co-
disposed with actively decomposing municipal solid
waste in a landfill. Thus, the test is designed to
Section 1004 (5) of the RCRA defines hazardous
determine the mobility of toxic constituents in wastes
waste as solid waste that may “pose a substantial
when exposed to organic acids. The adequacy of
present or potential threat to human health and the
DAFs of 100 was confirmed for all of the listed toxic
environment when improperly treated, stored,
constituents.
transported or otherwise managed.” RCRA Section
3001 charged EPA with the responsibility of defining
After particle size reduction, a liquid extract is
which specific solid wastes would be considered
obtained by exposing the waste to a leaching medium
hazardous waste, either by identifying the
(also called extraction fluid). In contrast to the EP,
characteristics of the waste or listing particular
which specified only one leaching medium, the TCLP
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
environmental concern. Specifically, the EP required Suggested Improvements for the Toxic
analyzing a liquid waste or liquid waste extract to Characteristics Leaching Procedure (TCLP).
determine whether it contained unacceptably high In February 1999, the Science Advisory Board’s
concentrations of any of 14 toxic constituents Environmental Engineering Committee (EEC)
identified in the National Interim Drinking Water prepared a commentary to call attention to the
Standards (NIPDWS). To account for the likely dilution need for a review and improvement of EPA’s
and attenuation of the toxic constituents that would current waste leachability testing procedure. The
occur as they traveled from the landfill to a drinking Committee’s single most important
water source, the EPA multiplied the NIPDWS by a recommendation is that EPA must improve
dilution and attenuation factor (DAF) of 100. The DAF leach test procedures, validate them in the field
of 100 was not derived from any model or empirical and then implement them. They recognized that
data. It is an estimated factor. the TCLP might require the development of
multiple leaching tests. The result may be a
more flexible, case-specific, tiered testing
In the 1984 Hazardous and Solid Waste Amendments
scheme or a suite of related tests incorporating
(HSWA), Congress directed EPA to expand the
the most important parameters affecting
toxicity characteristic (TC) and reevaluate its use of
leaching. Applying the improved procedures to
the EP to determine the toxic characteristics of a
the worst-case scenario could ameliorate many
waste. In response, the EPA developed a new test in
problems associated with current procedures.
1986 — the Toxicity Characteristic Leaching
Although the Committee recognized that these

53
modifications might be cumbersome to The aggressive agitation can dislodge or otherwise
implement, they felt this protocol might better create colloidal particles, which may pass through the
predict leachability. filtering process and subsequently be analyzed as
part of the extract. An over prediction of the aqueous
The TCLP model assumes 5% industrial solid waste phase as a constituent may result from hydrophobic
and 95% municipal solid waste in a sanitary landfill. organics and metals that preferentially bind to these
The TCLP specifies a procedure for liquid wastes, colloidal particles.
which are those with less than 0.5% dry solid material
and for wastes greater than or equal to 0.5% dry solid Particle Size Reduction: TCLP particle size reduction
waste. Liquid waste is filtered through a fine glass requirements may not represent field conditions.
fiber filter to form the TCLP extract, which is stored for Monolithic wastes have a lower leaching potential
later analysis. The solid phase may then undergo size caused by physical stabilization and the resulting
reduction. The EP required particle size reduction increase in length of diffusion pathway from waste into
through a 9.5-mm sieve. This requirement is retained the leachate. Additionally, some processes also
by the TCLP. In the TCLP, the waste must be ground provide for chemical stabilization by binding heavy
or milled until it passes a 9.5-mm sieve. Two metals in insoluble hydroxide and other complexes.
extraction fluids are used: One is a pH 2.9 acetic acid Reductions caused from solidification/stabilization of
solution for moderately to highly alkaline wastes and monolithic wastes are ignored.
the other is a pH 4.9 acetate buffer solution that is
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

54
undergo from repetitive precipitation of acid rain on a requirements of hazardous materials. EPA has
landfill to reveal the highest concentration of each allowed a variance to at least one company in
constituent that is likely to leach. This test is currently Phoenix, Ariz., in an effort to promote recycling and to
used in EPA’s delisting program and has been recognize that when used for metal recovery, these
designated method 1320 in the SW-846 manual. The materials are analogous to virgin raw materials used
MEP is intended to simulate 1,000 years of freeze- by primary smelters.
and-thaw cycles and prolonged exposure to a
leaching medium. Reportedly, one advantage of the
MEP over the TCLP is that the MEP gradually Toxic Release Inventory (TRI) System
removes excess alkalinity in the waste. Thus, the and Other Databases
leaching behavior of metal contaminants can be
evaluated as a function of decreasing pH, which
The Toxic Release Inventory (TRI) system is a
increases the solubility of most metals.
database of more than 300 designated toxic
chemicals released to the environment by
Hazardous Wastes manufacturers or businesses in the United States.
The inventory is updated yearly and provides a means
Under 40 CFR Chapter 1 (7-1-98 edition) solid wastes for interested persons to access information on toxic
that are subject to regulation as hazardous wastes are chemicals being released, stored or transferred to
identified under parts 261 through 265, 268, and parts their communities. This data has been made available
270, 272 and 124. Subpart A of the Chapter defines under the Emergency Planning and Community Right-
the terms solid waste and hazardous waste. It also to-Know Act (EPRA) of 1986. Under the Act,
identifies those wastes that are subject to regulation manufacturers and businesses are required to report
under parts 262 through 266, 268, and 270 and locations and quantities of toxic chemicals if the
establishes special management requirements for facility produces substantial amounts (more than
hazardous waste produced by conditionally exempt 25,000 pounds). This reporting became more
small-quantity generators and hazardous waste that is comprehensive following the Pollution Prevention Act
recycled. Subpart B sets forth the criteria used by (PPA) of 1990. The strategy focuses less on tracking
EPA to identify characteristics of hazardous waste and managing the waste and more on avoiding them.
and to list particular hazardous wastes. Subpart C Facilities are now required to indicate amounts of
identifies characteristics of hazardous wastes. chemicals that are recycled, used for energy recovery,
Subpart D lists particular hazardous wastes. and treated on site. Source reduction activities are
also noted. TRI is available on the Internet
In February 1999, EPA proposed a rule to promote (www.epa.gov/tri) and in various types of publications.
metal recovery from the hazardous waste water In addition, the Agency for Toxic Substances and
treatment sludge (F006, as regulated under RCRA). It Disease Registry (ATSDR) maintains the Hazardous
was proposed to encourage the legitimate recovery of Substance Release/Health Effects Database
metals from F006 waste that would otherwise be land- (HAZDAT). Chemicals on the Toxic Release Inventory
disposed. The F006 wastes generated from include antimony, arsenic, barium, beryllium,
electroplating processes in the metal finishing industry cadmium, chromium, cobalt, copper, lead,
generally contain recoverable amounts of metals. manganese, mercury, nickel, selenium, silver, thallium
Although some of this sludge is recycled for metals and zinc compounds, in addition to a long list of
recovery, a large percentage (according to EPA) is organic chemicals, acids and gases.
land-disposed. By minimizing the economic barriers to
recycling of F006 waste through metals recovery, EPA The National Risk Management Research Laboratory
feels this route will be more commonly sought. EPA has developed and is continuing to expand a
proposed to allow generators of F006 waste up to 270 database on the effectiveness of proven treatment
days to accumulate the waste on site without requiring technologies in the removal/destruction of chemicals
a hazardous permit, provided certain safeguard in water, wastewater, soil, debris, sludge and
conditions are met. Currently, only 90 days are sediment. This database gives performance data on
allowed. The EPA feels that the increased time will numerous technologies and is called the Treatability
allow larger shipments of F006 waste to be shipped, Database (TDB). TDB is available from NRMRL in
reduce transportation costs and provide additional Cincinnati, Ohio.
incentive to recover metals rather than dumping the
material. According to some industry sources,
however, this rule falls short of providing the Lead in the Workplace Directives (OSHA)
necessary incentive required for increased recovery of
metals from F006 sludges. Because these materials
The Occupational Office of Safety and Health
are classified as hazardous wastes, they are subject
Administration (OHSA) promulgates workplace and
to all the shipping, handling and licensing

55
safety rules for U.S. industries. On November 14, OSHA concluded that an 8-hour TWA airborne lead
1978, OSHA defined the lead standard (29 CFR concentration of 75 µg/m3 was the lowest
1910.1025) (43FR 52952). This standard required that economically feasible level that could be achieved by
employers achieve a lead exposure limit (PEL) of 50 means of engineering and work practice controls in
µg/m3 based on an 8-hour time-weighted average the brass and bronze ingot industry as a whole (60 FR
(TWA)(29CFR 1910.1025(c)). Both industry and labor 52856). Then on June 27, 1995, the Brass and
challenged the standard. The court found that OSHA Bronze Ingot Manufacturing association and the
had failed to establish feasibility of meeting the PEL Institute of Scrap Recycling Industries entered into an
for 38 of the industries covered and remanded OSHA agreement with OSHA acknowledging that this level
to reconsider the ruling. was economically feasible for the industry as a whole.
Based on the record, OSHA also recognized that most
In December 1981, OSHA published its new findings employers could not achieve the 50 µg/m3 PEL
for all but nine of the industries. The nine industries without supplemental use of respiratory protection,
included brass and bronze ingot and that it was not economically feasible to achieve
manufacturing/production, collection and processing even an 8-hour TWA of 75 µg/m3 in the briquetting
of scrap, nonferrous foundries and secondary copper and baghouse maintenance operations. Therefore,
smelting. In March 1987, the court asked OSHA to OSHA assumed the burden for proving economic
reconsider the application of the ruling for these feasibility in any enforcement proceeding under
remaining nine industries. On July 11, 1989, OSHA paragraph (e) (1) of the Lead Standard concerning
filed with the court additional reasons that compliance these operations. OSHA is allowing employers 6
with the PEL solely by means of engineering and work years from the date the court lifts the stay to comply.
practice controls was feasible for eight of the Follow-up instructions listing the new compliance date
remaining nine industries. OSHA felt that the ninth will be issued at that time.
industry, nonferrous foundries, could comply with the
PEL by means of engineering and work practice On February 27, 1997, the Directorate of Compliance
controls, but it was not economically feasible for small Programs published directive number CPL 2-2.67 to
nonferrous foundries to comply with paragraph (e) (1) change compliance requirements and compliance
of the ruling (54 FR 29142). Later, OSHA published dates for enforcement of the engineering and work
on January 30, 1990, a determination that the small practice controls provisions of the Lead Standard (29
nonferrous foundries could comply and achieve an 8- CFR 1910.1025 (e) (1). The stay on enforcement of
hour TWA airborne concentration of lead of 75 µg/m3 paragraph (e) (1) of the Lead Standard as it applies to
(55 FR 3146). Six of the nine industries challenged the brass and bronze ingot manufacturing industry
OSHA’s findings including brass and bronze ingot has not yet been lifted by the court. Until the stay is
manufacturing, collecting and processing scrap, the lifted, employers in this industry must continue to
nonferrous foundries and copper smelting. control lead exposures to 200 µg/m3 solely by
engineering and work practice controls, and to 50
On March 8, 1990, the court lifted the stay on µg/m3 by some combination of engineering and work
paragraph (e) (1) for all remanded industries (39 practice controls and respiratory protection. Six years
industries), except the six that challenged the after the judicial stay of the Lead Standard is lifted by
feasibility findings. The 39 industries were given two the court, the Compliance and Safety and Health
and one-half years to comply with the PEL. Officer (CSHO) shall determine whether the employer
Eventually, on July 19, 1991, the court reaffirmed in the brass and bronze ingot manufacturing industry
OSHA’s feasibility findings for five of the six contested is in compliance with all provisions of the Lead
industries, and lifted the stay. These industries Standard.
included the nonferrous foundries (large and small),
secondary copper smelting, and collection and OSHA posted the top 10 most cited violations for
processing of scrap. Employers in these three fiscal year 2010 for various industry sectors (American
industries were given until July 16, 1996, to comply. Foundry Soc., Govt Affiars, 8/2011). The violations
were not much different from past year’s. However,
With regard to the brass and bronze ingot for non-ferrous foundries, there was a large increase
manufacturing, however, the court concluded that, in the number of plants cited for overexposures to
while OSHA had shown it was technologically feasible lead. The top 10 OSHA violations for Non-Ferrous
to comply, it had not shown it was economically facilities: (1) Lead, (2) Respiratory Protection,
feasible to do so. The court remanded that portion of (3) Machines – general, (4) Occupational Noise
the record to OSHA for additional consideration and Exposure, (5) Hazard C9ommunication,
continued the stay of paragraph (e) (1) for the brass (6) Recordkeeping, (7) Annual Summary,
and bronze ingot industry. (8) Lockout/Tagout, (9) Design and construction
requirements for Exit Routes , (10) Personal
protective equipment – general.

56
Clean Air Act Ruling. Iron and steel scrap with baghouse control are subject
to a PM limit of 0.002 gr/dscf, or less. EPA chose to
The Clean Air Act is the comprehensive federal law apply a PM limit of 0.002 gr/dscf as GACT to all
that regulates air emissions from area, stationary and melting furnaces and other furnaces that process
mobile sources. This law authorizes the U.S. EPA to molten metal at a new secondary copper smelter. This
establish national Ambient Air Quality Standards is consistent with the UN Environment Programme’s
(NAAQS) to protect public health and the guidelines on performance standards for new
environment. The Act was amended in 1977 to set secondary copper smelters (available at
new goals and dates for achieving NAAQS deadlines. http://www.pops.int/documents). These guidelines
The 1990 amendments were intended to meet recommend PM removal systems such as fabric filters
insufficiently addressed problems such as acid rain, or bag houses and state that these systems should
ground-level ozone, stratospheric ozone depletion and achieve a PM level of 5 milligrams per cubic meter
air toxics. On February 28, 2001, the U.S. Supreme (.002gr/dscf) for new secondary copper smelters. The
Court ruled unanimously that federal law doesn’t allow final rule (Jan 23, 2007) applies only to secondary
the EPA to consider expense to industry when it sets copper smelters and does not apply to copper, brass,
clean-air standards and permissible pollution levels. and bronze ingot makers or remelters that may also
The Court agreed with the fundamental principle that be included under this NAICS code.
the Clean Air Act was designed to protect people’s
health without regard to cost. However, the ozone As a result of the tightening in the federal National
standards can’t be implemented until the case goes Ambient Air Quality Standard (NAAQS), the Illinois
back to the U.S. Court of Appeals for the D.C. Circuit Environmental Protection Agency (EPA) brought a
to assure that EPA reaches a lawful and reasonable NAAQS lead suit against an Illinois-based ingot maker
interpretation of ozone standards and enforcement in 2011. The lead standard had been revised to 0.15
policies. Beyond the cost factor, the Court ruled that micrograms per cubic meter of air from the previous
Congress did not unconstitutionally delegate its power standard of 1.5 micrograms per cubic meter. The new
to EPA. The rules affect airborne soot and smoke standard was started in January 2009. (Recycling
from trucks and power plants, as well as smog or Today, May 2011)
ground-level ozone from chemical plants and other
sources. The 1997 standards limit ozone to 0.08 parts The current popularized movement toward regulation
per million, instead of 0.12 parts per million under the of carbon dioxide emissions under the Clean Air Act,
old requirement. or through any new regulation (Carbon Cap and Trade
Act) promises to have significant negative impact on
For current rules and regulations for clean air act the copper industry. The U.S. EPA’s proposed
ruling, seek www.epa.gov on the internet and select guidance for regulating greenhouse gas emissions
Clean Air Act. Information may also be found for the was released in mid-November, 2010 and is set to go
Clean Water Act on this site. into effect on January 2, 2011. Many analysts
challenge EPA’s authority to establish the mandate,
The U.S. EPA published new rules in the Federal which will increase economic regulation dramatically.
Register for National Emission Standards for Because the guidance will apply only to major
Hazardous Air Pollutants (NESHAP) on January 23, modifications to existing plants and new construction,
2007 (Vol. 72, No. 14). The U.S. EPA’s proposed many manufacturers will forgo building newer, more
guidance for regulating greenhouse gas emissions innovative production plants and updating older, less
was released in Mid-November, 2010. (Research and efficient ones.
Commentary, EPA) and was set to go into effect on
January 2, 2011. A short commentary period was The State of Texas was suing the EPA, claiming the
being allowed. This followed the proposed rules decision to regulate carbon dioxide is based on flawed
published on October 6, 2006 in the Federal Register. science (www.examiner.com). The Competitive
With regard to rules applying to the secondary copper Enterprise Institute warned small businesses
smelter industry, both reports are worth reading. The exempted by the “tailoring” rule. This rule temporarily
principal observations called attention to the fact that exempts them from certain mandates, but businesses
there are currently no secondary copper smelting were warned to remember that Congress never
facilities operating in the United States that qualified authorized EPA to make climate change policy in the
for specific air quality applications. However, should first place (Marlo Lewis. 2010 Cei.org/news
any new facility be constructed, brief releases/EPA Offers Draconian “Guidance” for Global
recommendations were proposed in both reports to Warming Energy Restrictions)
ensure that any potential emissions will be
appropriately controlled. Baghouses were identified as Given the unfair trade, environmental and tax effects
the most effective particulate matter (PM) control on the industry over the past ten years, this may just
devices to be used on cupolas and other furnaces. be the “nail” in the coffin. In the opinion of the author,

57
the notion that man-driven carbon dioxide generations
are the cause of increased Global Warming, or of any
significant worldwide climate change, is the world’s
greatest hoax of the century. That this philosophy
should be used to levy unfair penalties on the U.S.
manufacturing and metal industries is next to criminal
in design. That man can control climate in the world is
surely the most presumptuous assertion ever made.

For a discussion on this problem and the scientific

facts relating to it, the reader is directed to the
following internet links at
www.globalwarmingheartland.org and at the US
Senate Committee on Environment and Public Works:
Matt_dempsey@epw.senate.gov. This committee
has done a tremendous job of tracking and
summarizing the scientific testimony on this issue. Of
interest is the fact that solar irradiance correlates well
with Arctic temperature, while hydrocarbon use does
not (see Ref. 65, Robinson (2007)). In addition, a
650,000 year ice-core record does not agree with a
hypothesis of “human-caused global warming, ” but
instead gives empirical evidence that invalidates this
hypothesis.

58
CHAPTER 5: • Loss of production lines and management
Problems and Solutions positions associated with plant closings

• Diminishing approved landfill space

The Problems accompanied by increased tipping fees

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

59
kilograms of copper. About 4.3 and 4.6 thousand domestic recycling industry by creating competitive
metric tons of copper were recovered in the United jobs overseas. (Resource Recycling p.8. Dec. 2011)
States by recyclers in 1997 and 1998, respectively. In
1998, about 2.6 million personal computers were Radioactive metals. As nuclear plants are
recycled in the United States. decommissioned, storage and disposal of the slightly
radioactive scrap metals derived from them become
Some recyclers have been shipping components more of a problem. The Environmental Protection
overseas for dismantling by hand. Because labor is Agency (EPA) and Nuclear Regulatory Commission
less expensive in China and Taiwan, and hand (NRC) have been concerned about risk imposed on
dismantling results in less waste than shredding, the public from the recycling of radioactive
much of this material had been headed there. This contaminated metals. Since the mid-1990s, EPA has
traffic may not continue at the same pace in the been studying the risk involved with recycling of
future, owing to a new environmental awareness in slightly radioactive metals from NRC licensees. More
China and new tariffs against the import of scrapped recently, the NRC has been looking into the feasibility
electronic parts. China threatened to crack down on of recycling dismantled nuclear plant metal through
illegal imports of junked computers and other commercial metal processors. Unfortunately, there are
electronic scrap. In Guiyu, China, stacks of broken very few qualified secondary copper refiners
computers and electronic parts filled unused rice remaining in the United States.
paddies, and circuit boards were being melted over
open fires. A substantial tariff was levied in May 2002 According to Bryan and Dudley (1974), approximately
on what China called “Class 7” copper scrap and 694 tons of copper, 250 tons of bronze and 10 tons of
blocked containers of copper scrap from entering the brass are used to construct a typical light water
country. Some U.S. brokers considered the measure reactor facility. Copper is used in turbine generators,
severe and likely to affect U.S. copper exports to reactor equipment, heat transfer systems and
China. This did not have an immediate effect, since miscellaneous instrumentation and control systems.
U.S. scrap exports to China continue unabated Much of the metal at DOE facilities and NRC licensed
through 2007. China’s scrap imports i through 2010 sites is not contaminated, and can be released without
were at record levels (Table 4). In the meantime, with a problem. It is estimated that copper associated with
commodity prices at record highs and innovative electrical plant equipment amounts to about 557 tons
electronics recycling methods becoming increasingly and that the total mass of uncontaminated (clean)
cost effective, new value is being found in all post- copper is about 580.3 tons. The remainder, only about
industrial and post-consumer scrap. 62 tons, is slightly contaminated. At the end of 1999,
there were 104 operating nuclear power reactors and
China began to implement its Waste Electrical and 37 operating non power reactors in the United States.
Electronic Equipment (WEEE) Recycling Management The normal duration of a nuclear power reactor
Regulations at the start of 2011. (Recycling Today, license is 40 years, some with 20 year extensions.
Nov. 2011, p. 87) China passed its own WEEE Shutdown dates range from 2006 to 2030, among the
regulation because household electronics scrap facilities currently licensed to operate. The total
generation is expanding at an annual rate of 20%, amount of potentially contaminated recyclable metal is
according to CNMIA reports. not much compared with the millions of tons of refined
copper consumed by the U.S. industry each year.
In 1984, Noranda in Canada began processing small However, this small amount of contaminated metal is
amounts of electronic scrap and, by 1999, was the of great concern to the processing industry. According
largest electronics recycling plant in North America to some sources (www.sierraclub.org) more than 1.6
(USGS, 2001). There is value contained in the million tons of iron, steel, aluminum and copper metal
monitors and CRT’s, but Noranda must charge a fee were in storage by 1997 waiting for the EPA green
for cover the handling costs. The fee is normally light.
several hundred dollars per metric ton.
Increasingly, EPA has received complaints from scrap
A relatively new organization, Coalition for American dealers and refiners that in receiving hot scrap, they
Electronics Recycling (CAER), urged support for the are having to pay for cleanup when their scrap yards
Congressional Responsible Electronics Recycling Act and plants become contaminated. As a general rule,
(HR2284 and S1270), which calls for restrictions on copper refining facilities will not accept material that is
export of electronic scrap to developing countries. radioactive. Those that have unwittingly done so by
The CAER includes a roster of 29 U.S. electronics mistake have paid millions of dollars to undo the
recycling firms in 34 States, including refurbishers, damage. One company in the early 1990s
scrap processors and refiners. CAER argues that unknowingly shipped some radioactive slag, which
current policy for export of electronics harms the resulted from fire-refining a contaminated bus bar, to a
company in Canada for further processing. The

60
Canadian company did an analysis and refused the This is also potential trouble from a national security
shipment, resulting in costly storage, permitting, point of view. Secondary smelters are essential during
shipment and hazardous dump fees for the victimized wartime buildup and scarcity of primary raw materials.
U.S. company.
In 1999, the National Electrical Manufacturers
Industry Solutions Association (NEMA) petitioned the EPA to delist
copper from its Toxic Release Inventory (TRI)
In talking to industry representatives, one finds because it felt that recycling prevents most copper
enthusiasm for the various methods and equipment from entering the environment. There also was
they have developed for coping with heightened growing evidence that copper was not detrimental to
environmental awareness. Most of the surviving the environment as previously theorized. Public
industry has managed to solve many of the pollution access to information on the TRI list could cause
problems in their particular part of the industry and are undue public concern and stigmatize some of its
proud to be a part of the solution. In addition to solving members. In 1997, the TRI report indicated that
the environmental and labor health problems posed 34,500 tons of copper had been released to the
by EPA and OSHA, many in the industry also are environment. A similar petition to delist copper in 1996
striving to achieve ISO 9000 and ISO 14000 quality was rejected (American Metal Market, 1999).
standards to maintain high-quality goals in their
production processes. Process Recovery Corp. The need for improved,
cost-effective technologies and management
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

61
include service providers as well as manufacturing electronics recycling process yielded about 410,000
companies. In 1994, ISO 9000 was again revised and tons of recyclable materials in 2001
published internationally. In particular, the sections (http://www.iaer.org). The IAER estimates that 3 billion
covering Process Control, Corrective Actions and consumer electronic units will be scrapped during the
Servicing were strengthened and clarified. Today, the rest of this decade, or an average of 400 million units
ISO 9000 Standards Series has all but replaced other, per year. The electronics recycling industry is
more parochial standards for doing business and expected to increase capacity by a 4 or 5 times factor
guaranteeing quality. In only a few short years, the by the end of this decade.
term ISO 9000 has become synonymous with quality
in almost every language used to conduct trade and Globally, e-scrap has become the fastest growing
commerce. These standards require strict methods of waste stream with 20-50 million tons of e-scrap
procedure and labor training. The results have been reportedly generated worldwide annually. Increased
better, more streamlined operations and improved awareness of potential hazards from electronic scrap
markets for their products. and the need for efficient and cost effective disposal
solutions are increasing.
The American National Standards Institute (ANSI) and
the Registrar Accreditation Board (RAB) established The U.S. EPA provides information on how and where
an accreditation system in response to the need to to donate, or to safely recycle old electronics – namely
accredit registration bodies as required by ISO 14001, TVs, computers and cell phones—with links to vendor
14010 and 14011. The ANSI-RAB National and retailer recycling program information.
Accreditation Program Criteria (NAP), published (www.epa.gov) Another site, E-cycling Central
September 13, 1996, specifies requirements for a (www.eiae.org) from the Electronic Industries Alliance,
registration body. Audit teams from the registration offers a state-by-state recycling directory and
body go out to organizations seeking registration and information about national programs. The
compliance with ISO 14001 standards. ISO 14001 Environmental Issues Council of the Electronic
requires an organization to have an environmental Industries Alliance has organized the Consumer
policy statement that includes: a commitment to Education Initiative to inform consumers about
prevention of pollution, a commitment to continual recycling and reuses of used electronics, including
improvement, and a commitment to compliance with computers.
relevant legislation and regulations. Top management
is to define the organization’s environmental policy Some U.S. and Canada scrap handlers use shredders
and ensure that it includes a commitment to comply on electronic scrap, but some also hand dismantle
with relevant environmental legislation and these materials, charging a fee to make the process
regulations. economically viable. When considering electronics,
there are environmental concerns with the disposal of
In September 1996, ISO determined that there was these items, as they contain potential hazards. Some
insufficient support to proceed in developing organizations take older computers and parts for
international voluntary consensus standards on reconstruction, redistribution and resale. Some parts
occupational health and safety management systems of Europe and Mexico, reportedly, have found use for
(OHSMS). One of the reasons stated was that computers that might be considered outdated by U.S.
national or regional standards are different, owing to standards. However, reuse is not possible for all of the
different socioeconomic conditions and cultural discarded electronics. Most recyclers test for reusable
differences. There is little to harmonize, and, components before completely dismantling the items.
therefore, an ISO OHSMS standard would not What cannot be reused can be processed, usually by
facilitate international trade. In addition, companies hand dismantling, or by shredding, to retrieve metals
have not had sufficient experience in evaluating the such as copper, steel, aluminum and the precious
benefits and effectiveness of ISO 9000 quality metals.
management systems and ISO 14000 environmental
management systems standards. The costs A handful of states are mandating “take-back”
associated with implementing an OHSMS standard programs and industry has begun to respond. Sony
would outweigh the potential benefits. Corp announced in August 2007 a recycling scheme
to process Sony-brand electronics castoffs. Waste
Electronic Scrap. Although handling electronic scrap Management Inc., Sony’s partner in this venture
has been a growing problem in the United States, new already sells materials such as copper retrieved from
companies are being formed and improved methods e-waste. Sony will try to raise awareness and make
are being adapted to address the problem. The recycling a lot more convenient than it is today.
International Association of Electronics Recyclers Treating recycling as a business, not a money pit,
estimates that there are about 400 electronics marks a turning point for the industry.
recycling companies in the United States, and that the

62
On April 1, 2011, New York State passed the USEPA and other governmental agencies have been
Electronic Equipment Reuse and Recycling Act, a law working to develop procedures to ameliorate and
requiring manufacturers of a host of electronic develop brownfield sites. The USEPA’s Brownfields
products to create and fund a plan to collect and Initiative strategies include funding pilot programs and
recycle these at the end of their useful lives. This other research efforts, clarifying liability issues,
“extended producer responsibility” (EPR) law is the entering into partnerships, conducting outreach
22nd of its kind in the United States, but it is activities, developing job training programs, and
considered by many to be the most comprehensive. addressing environmental justice concerns. The
USEPA has been working with states and
A standard for electronics recycling was developed by municipalities to develop guidance that will provide
the Basel Action Network (BAN) in Seattle, WA. some assurance that, under specified circumstances,
Companies must be certified to the e-Stewards prospective purchasers, lenders and property owners
Standard for Responsible Recycling and Reuse of do not need to be concerned with Superfund liability.
Electronic Equipment. This certification publicly
validates and extends long-term policies of being a In 2006, EPA awarded 8 brownfields grants to Illinois
conscientious electronics recycling and end of life communities, including the bankrupt North Chicago
service company. (Recycling Today, 8/31/2011) Smelting and Refining of R. Lavin & Sons. A
$200,000 grant was given to clean up hazardous
Lead in Potable Water. On September 20, 2007, the material on the R. Lavin property in Chicago and to
American Foundrymen’s Society (AFS) held a develop a brownfield site. (EPA News Release,
meeting to discuss the implications of the recent 5/15/2006)
potential California legislation (AB1953) that will
further restrict the acceptable level of lead in potable In 1977, Congress enacted the Community
water applications. The Copper Development Reinvestment Act (CRA) to require banks, thrifts and
Association and the industry have been working on other lenders to make capital available in low- and
lead substitution in several copper alloys for some moderate-income urban neighborhoods.
time. Although bismuth (EnviroBrass I, II and III) and Environmental concern and financial liability for
other alloys)alloys have been consistently suggested cleaning up these sites has made potential investors
as leading candidates, the limited source of the metal reluctant to undertake this development. Rather than
has been a principal worry. There are several of these reuse former urban industrial sites, businesses have
alloys now available on the market. The alloys known instead moved to suburban or rural Greenfield areas,
as EnviroBrass use a combination of bismuth and which carry fewer risks to development.
selenium to replace lead. These alloys were
developed by a broad-based consortium led by the On September 30, 1996, as part of the Omnibus
American Foundrymen's Society with funding and Appropriations Bill, the Asset Conservation, Lender
technical input from the CDA and the Brass and Liability, and Deposit Insurance Protection Act of 1996
Bronze Ingot Manufacturers, and including several was passed. The Act includes lender and fiduciary
foundries and plumbing products producers. While the liability amendments to CERCLA, amendments to the
basic properties tend to be comparable to their leaded secured creditor exemption set forth in Subtitle I to
counterparts, they are more expensive. It is not known RCRA, and validation of the portion of the CERCLA
how widely these alloys can be practically applied. Lender Liability rules. In addition to specific guidance,
the EPA is exploring other ways to address the fear
that affected parties may have concerning Superfund
liability at previously used properties.
Government Solutions
On August 5, 1997, the Taxpayer Relief Act was
Because liability concerns have been a problem, passed and included a new tax incentive to spur the
interest in brownfield redevelopment has surged over cleanup and redevelopment of brownfields in
the past decade, owing to a combination of federal, distressed urban and rural areas. In 1997, several bills
state and local programs aimed at reducing regulatory also were introduced in Congress to establish a
burdens and mitigating liability. Congress also has process and funding for states to work with the EPA
recently been taking an interest. A brownfield is a site, and industry in voluntary cleanup programs. The bills
or portion thereof, that has actual or perceived are currently stalled, while debate over retroactive
contamination and an active potential for liability continues. To date, 36 states reportedly have
redevelopment or reuse. CERCLA establishes the implemented, or are in the process of implementing,
liability regime that affects brownfield sites as well as voluntary cleanup programs. A state’s brownfield
Superfund sites. While brownfield cleanups typically cleanup program can provide relief only from action
cost much less, the contamination extent is usually under state law, and the possibility of federal action
unknown. Several state environmental agencies, the cannot be eliminated. In 1996, EPA had signed State

63
Memoranda of Agreements (SMOAs) with 11 states to States, some manufacturers and retailers have helped
help them develop cleanup programs, giving the states and municipalities sponsor electronics recycling
states a lead role in addressing sites not on the programs. Some states have also enacted legislation
Superfund National Priority List, and delineating to place restrictions on the disposal of products
clearly the roles of states and the EPA. containing hazardous material to encourage
manufacturers to reduce the use of certain materials
In November 1999, Congress passed the Superfund (Recycling Today, Feb. 2002).
Recycling Equity Act (SREA) of 1999, which
exempted a broad scope of scrapped material from OECD has been doing workshops since 2005 on its
liability to “promote the reuse and recycling of scrap Sustainable Materials Management (SMM) initiative.
material in furtherance of the goals of waste The goal is to explore policy opportunities and barriers
minimization and natural resource conservation, while for SMM to demonstrate use of the SMM concept for
protecting human health and the environment” policy making. In recent years, manufacturing
(S.1528). While including a wide variety of scrapped, companies have been redirecting efforts towards
economically viable materials, this bill fell short of also sustainable manufacturing to integrate approaches
including those valuable recyclable secondary by- that take into account a product’s life-cycle impacts.
products of copper and copper alloy scrap processing (www.oecd.org/sti/innovation/sustainale
that also have markets. SREA was designed to manufacturing)
protect recyclers who had acted in good faith. If a
smelter site or landfill was later declared a Superfund In September 2003, California passed the Electronic
site, the recycling industry was often cited as partially Waste Recycling Act, the first law of its kind in the
responsible parties (PRPs) because they had done United States. It bans the export of e-waste to foreign
business with them. The ISRI was key in getting this countries that don’t meet environmental standards.
legislation passed. In 2010, EPA was reexamining The law provides for collection of a surcharge from
Superfund sites. This included wood product consumers at the point of purchase to fund recycling.
manufacturing, fabricated metal product It also requires manufacturers to eliminate certain
manufacturing, electronics and electrical equipment hazardous ingredients from electronics sold in
manufacturing and facilities engaged in the recycling California.
of hazardous materials (CERCLA). The SREA may
exempt some recycling activities from the additional New technical guidelines are also being developed
EPA research. with the Basel Convention to address concerns that
some developing countries lack facilities to cope with
A new EPA rule, intended to clarify RCRA, was piles of plastic wastes of all kinds. The recycling of
proposed in June 2002. The new rule was expected to wire and cable is getting special attention from the
ease restrictions that have caused many cities and group. It is unclear how vigorously developing nations
recyclers to shy away from recycling cathode ray would enforce any burning ban, or whether it would
tubes (CRTs), which is one of the largest sources of cause more recycled wire to remain in the United
lead in solid waste dumps, and cabling and older States. Some researchers claim the burning of PVC
casings, which contain polyvinyl chloride (PVC). Other plastics produces persistent organic pollutants that
nations are taking a look at how to handle electronics circulate globally. The Basel delegates have adopted
in their recycling and waste streams, and a set of technical guidelines for burning of certain
manufacturers are also involved. types of plastic, according to the Environmental News
Service (ENS).
The Organization for Economic Cooperation and
Development (OECD) began examining the New European rules on recycling old cars will force
electronics waste issue in October 2001. The OECD Britain’s scrap yards and dismantling companies to
Working Group on Waste Prevention and Recycling is invest around $750 million on new tooling and
developing a program to give greater assurance of equipment. Under the directive on so-called end-of-life
proper management of recyclables being exported vehicles, scrap operators will need to remove all
and to take a close look at management of electronics fluids, glass and reusable metal and plastic parts from
recycling. Guidelines are expected for members who old cars before they are dismantled. The British
rely on third party auditing to ensure that hazardous Metals Recycling Association has warned that the
materials are handled in a safe manner. The Basel investment costs will be passed on to vehicle owners.
Action Network is also working toward developing Some two million vehicles per year are scrapped or
guidelines to stop the export of hazardous wastes. dismantled in Britain.
The European Union has proposed a Waste Electrical
and Electronic Equipment (WEEE) Directive that will In 2009, the Department of Defense Surplus LLC
give manufacturers responsibility for recycling their started implementing new requirements for the
products when they are discarded. In the United mutilation of fired shell casings. These requirements

64
would prevent shell casings from being reused or dealers for accepting illicit goods. The Michigan state
reconstructed. This meant that private citizens could law passed in 2008 is an example. In order to sell
no longer purchase this brass and most of this was to scrap metal, the new law required sellers to: present
go to foundries to be melted and likely exported. This suitable ID, allow the buyer to take a thumbprint, sign
move effectively stopped the remanufacturing of a statement indicating they are the owner or are
ammunition for domestic civilian and law enforcement authorized to sell the metal, and, sign a statement that
use. In 2010, however, the House of Representatives they have not previously been convicted of metal
added language to this year’s National Defense theft. The dealers are also required to maintain
Authorization Act (HR5136) that would ensure records of purchases and tag and hold nonferrous
serviceable surplus ammunition and once-fired small metal for 7 calendar days.
arms cartridge cases would be made available for
domestic commercial sale. With widespread Some countries are taking more drastic measures to
ammunition shortages for local sportsmen, reloaded stem copper scrap thievery. Jamaica announced in
ammunition costs considerably less, and is used July 2011 a ban on export of all scrap exports.
widely for marksman ship training and competition by Arrangements were made for companies generating
civilians. (American Rifleman, August 2010, p. 8) their own scrap to obtain permits and have
inspections of containers and scrap locations.
Radioactive Metals. In July 1997, S. Cohen and (Recycling Today, 7/27/2011)
Associates, under contract to EPA, produced a report In September, 2011, California proposed stricter rules
on recycling of scrap metals from nuclear facilities for the metal casters of San Francisco area. The Bay
(Evaluation of the Potential for Recycling of Scrap Area Air Quality Management District
Metals from Nuclear Facilities, July 15, 1997). A (BAAQMD)hoped to reduce air pollution through
further analysis containing revised impacts on the free stricter requirements. The metal casters already
release of scrap metal from nuclear facilities on follow strict environmental standards and the new
exposed individuals and answering questions and rules would mean another significant financial
concerns raised during the review process was issued investment, an estimated $20 million per plant. This
in 2003. These investigations are ongoing, but a more could force some metal casting facilities to close or
recent report has not yet been released by the EPA or cut back on staff. (Modern Casting, Sept 2011, p. 3)
the U.S. Nuclear Regulatory Commission (NRC).

A report in the April 3, 2003, American Metal Market,

indicates that a last minute amendment was added to
the House Energy Policy Act of 2003 that could
prevent radioactive scrap metals from being released
into the commerce stream. While release of
contaminated scrap is currently under a moratorium,
metals interests have been lobbying for a more
permanent solution. The Metals Industries Recycling
Coalition (MIRC) urged support of the provision. MIRC
felt that residual radioactive contamination in scrap
metal imposed significant costs on metals producers
in detection processes and in costly plant shutdowns
and cleanup, if an undetected source was accidentally
melted. MIRC’s position was that radioactively
contaminated scrap metal originating at impacted or
restricted areas at NRC-licensed facilities must be
disposed of in a way that prevents the release of this
scrap into the stream of commerce – whether by
requiring disposal at a licensed low-level radioactive
waste facility or at an appropriate solid-waste landfill,
or by requiring that the metal be recycled for restricted
use within the NRC’s licensing scheme.

Material Theft. During the period 2004-2008, and

again in 2010-2011, higher copper prices prompted a
severe uptick in theft of copper products. Theft had
become a serious problem throughout the United
States. To counteract this situation, many States
have enacted legislation that would penalize scrap

65
Table 1. LME, COMEX and U.S. Refined and Scrap Prices
Table
(U.S. 1. LME, COMEX and U.S. Refined, Scrap and Ingot Prices
Currency)
(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 305 309 316 261 291 105
2007 323 323 329 283 311 137
2008 315 313 319 279 301 144
2009 234 237 242 206 227 113
2010 342 343 NA 298 325 164
2011 400 398 NA 351 389 188
1/
2012 361 362 NA 324 356 195

Source: Metals
Source: Week,
Metals American
Week, Metal Metal
American Market,Market,
ICSG Copper
ICSGBulletin,
CopperU.Bulletin,
S. Geol. U.
Survey Min. Ind.
S. Geol. Survey
Survey andInd.
Min. Compendium.
Survey and Compendium.
1/
Scrap prices are based on 9 months average of 2011. Refined prices are full year averages
1/
Scrap prices are based on 7months average of 2012. Refined prices are full year averages

Statistical Information 70

Statistical Information 66
 Table 2A. World Copper Recovery from All Sources 1
(thousand metric tons)
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
1971 2,173 803 1,237 3,653 202 8,301 37
1972 2,242 894 1,359 4,047 208 9,061 35
1973 2,488 930 1,574 4,007 204 9,548 37
1974 2,400 1,025 1,695 4,029 220 9,753 35
1975 2,196 941 1,464 3,462 214 8,725 31
1976 2,385 1,001 1,638 3,827 213 9,527 33
1977 2,358 987 1,735 3,969 218 9,777 32
1978 2,316 933 1,811 4,225 213 10,065 34
1979 2,300 897 1,909 4,686 214 10,575 37
1980 2,456 952 2,058 4,375 209 10,657 38
1981 2,462 918 2,259 4,590 240 11,046 36
1982 2,432 969 2,258 4,029 224 10,510 36
1983 2,477 1,040 2,419 3,969 245 10,762 35
1984 2,504 1,023 2,421 4,141 245 10,962 36
1985 2,564 976 2,530 4,122 235 11,065 37
1986 2,659 963 2,718 4,163 223 11,395 36
1987 2,636 921 2,837 4,419 258 11,730 37
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 3,477 365 5,761 7,315 512 19,362 35
2001 3,551 416 5,865 7,495 582 20,052 32
2002 3,432 450 5,998 7,005 563 19,536 31
2003 3,275 454 6,531 6,665 504 19,514 31
2004 3,209 508 7,046 6,772 510 20,350 32
2005 3,077 509 7,973 6,731 484 21,093 32
2006 3,068 529 9,132 6,724 454 22,230 34
2007 2,928 589 9,442 6,703 460 22,397 32
2008 2,942 603 10,924 6,477 520 23,666 35
2009 2,522 709 9,727 6,395 452 21,914 30
2010 2,773 874 11,408 6,257 424 23,993 34
2011 2,847 969 11,649 6,155 477 24,271 33
2012 2,942 964 11,680 5,775 475 24,366 33

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

1/
IncludesInternational
Data sources: primary andCopper
secondary copper
Study production
Group, USGS, USBM.in refined and direct melt scrap.
1/
Includes primary and secondary copper production in refined and direct melt scrap.

Statistical Information 71

67 Statistical Information
Table
Table 2B. World
2B. World Production
Production of Refined
of Refined Copper
Copper, by Source
by Source
(thousand metric tons and
(thousand metric tons and percent of total) percent of total)

Percent
Year Primary Secondary SX-EW Total Secondary
Refined Refined Refined Refined Refined
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 6,751 1,439 213 8,403 17
1986 7,050 1,313 279 8,643 15
1987 7,006 1,484 332 8,823 17
1988 8,323 1,756 431 10,510 17
1989 8,443 1,926 543 10,911 18
1990 8,188 1,945 660 10,792 18
1991 8,055 1,930 689 10,675 18
1992 8,340 1,946 754 11,041 18
1993 8,617 1,880 763 11,260 17
1994 8,472 1,808 830 11,110 16
1995 8,675 2,101 1,069 11,846 18
1996 9,226 1,984 1,463 12,673 16
1997 9,627 2,109 1,759 13,495 16
1998 10,002 2,055 2,005 14,063 15
1999 10,129 2,103 2,316 14,548 14
2000 10,312 2,125 2,325 14,762 14
2001 11,122 1,862 2,599 15,583 12
2002 10,790 1,898 2,649 15,337 12
2003 10,745 1,786 2,723 15,254 12
2004 11,132 2,070 2,706 15,908 13
2005 11,718 2,164 2,694 16,576 13
2006 11,850 2,596 2,823 17,269 15
2007 12,130 2,747 3,004 17,881 15
2008 12,209 2,823 3,098 18,130 15
2009 12,077 2,839 3,283 18,199 16
2010 12,399 3,230 3,344 18,972 17
2011 12,684 3,484 3,483 19,651 18
2012 12,740 3,591 3,686 20,018 18

DataSource:
Data Source: International
International Copper
Copper Study Study
Group. Group
e
e Estimated
Estimated

Statistical
StatisticalInformation
Information 72 68
Table 2C. World Consumption of Copper in Direct Melt Scrap 1

(thousand metric tons, copper content)

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 1,682 15 1,651 1,228 25 4,601 1,102 24
2001 1,823 0 1,517 1,108 22 4,469 977 22
2002 1,585 0 1,516 1,078 20 4,200 960 23
2003 1,558 0 1,716 966 20 4,260 891 21
2004 1,564 0 1,868 990 20 4,442 914 21
2005 1,404 0 2,112 986 15 4,517 904 20
2006 1,346 0 2,547 1,043 25 4,961 909 18
2007 1,255 0 2,198 1,045 18 4,516 876 19
2008 1,148 0 3,570 802 18 5,537 738 13
2009 779 0 2,152 779 6 3,715 728 20
2010 930 0 3,350 741 0 5,021 694 14
2011 889 8 2,990 733 0 4,620 705 15
2012 e/ 996 0 2,642 710 0 4,348 697 16

Data
Datasources:
sources:International
Int. CopperCopper StudyU.S.
Study Gp., Group,
Bur.U.S. Bureau
Mines, of Geological
U. S. Mines, U.S.Survey.
Geological Survey.
11/
Reportedforforsome
Reported some countries,
countries, such
such as the
as the United
United States,
States, but estimated
but estimated for others
for others basedbased on semis
on semis production.
production.
22/
Revised
Revisedtoto
include copper
include from
copper other
from thanthan
other copper-base scrap.
copper-base scrap.
e
Estimated on 9 months data.

Statistical Information 73
69 Statistical Information
 Table 2 D. World Recovery of Copper From Copper-base Scrap, by Area
Table 2D.metricWorld
(thousand Recovery
tons, copper content) 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
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 2480 1574 2213 25 459 6726 37 23 33 0
2001 2376 1392 2018 22 546 6331 38 22 32 0
2002 2273 1222 2199 20 404 6097 37 20 36 0
2003 2162 1098 2410 20 376 6046 36 18 40 0
2004 2152 1125 2731 20 503 6512 33 17 42 0
2005 1952 1115 3101 15 512 6681 29 17 46 0
2006 1894 1178 3849 25 641 7557 25 16 51 0
2007 1818 1209 3667 18 573 7263 25 17 50 0
2008 1779 968 5094 18 523 8360 21 12 61 0
2009 1386 917 3817 6 437 6553 21 14 58 0
2010 1569 870 5363 0 453 8251 19 11 65 0
2011 1599 877 5221 0 418 8103 20 11 64 0
2012 e/ 1709 850 4952 0 432 7939 22 11 62 0

Data
DataSources:
Sources: ICSG,
ICSG, USBM,
USBM, U.S.
U.S. Geological Survey.
Geological Survey.
e/e
Estimatedon
Estimated on97months
monthsdata.
data.

Statistical Information 74
Statistical Information 70
 Table 3. World Copper and Copper Alloy Scrap Exports
(thousand metric tons, gross weight)
Table 3. World Copper and Copper Alloy Scrap Exports
(thousand metric tons, gross weight)

2005 2006 2007 2008 2009 2010 2011 2012

(e)
Australia 87 50 49 51 62 74 80 0
Austria 33 40 40 42 54 54 56 70
Belgium 178 162 189 153 108 150 166 146
Canada 120 165 165 152 148 158 182 171
Chile 37 55 102 72 69 120 69 19
China 6 7 5 3 2 2 2 2
Czech Rep. 54 57 58 60 105 122 85 72
Denmark 26 31 31 36 31 31 33 28
Finland 31 31 33 33 33 33 34 30
France 262 294 280 263 229 287 306 308
Germany 476 499 481 479 450 578 585 590
Greece 15 17 15 12 16 22 19 23
Hong Kong 121 130 153 116 70 130 85 78
Indonesia 32 51 55 41 35 46 43 39
Ireland 13 16 10 22 46 7 10 10
Italy 113 104 120 149 158 167 173 190
Japan 424 412 425 396 360 286 288 312
Kazakhstan 2 6 9 12 16 24 11 1
Malaysia 75 36 29 17 29 37 30 17
Mexico 105 126 122 129 109 126 116 143
Morocco 15 18 17 9 13 26 35 36
Netherlands 182 310 237 225 268 289 308 315
Norway 23 24 24 23 25 38 46 40
Peru 2 5 7 6 6 7 7 7
Philippines 15 26 20 19 23 21 26 26
Poland 48 55 69 87 54 55 60 50
Portugal 35 30 21 19 20 23 36 43
Rep. of Korea 161 202 216 192 187 100 85 92
Russian Fed. 2 4 0 3 1 2 0 0
Saudi Arabia 60 127 105 0 57 94 63 0
Singapore 43 35 28 20 9 14 18 34
Slovakia 15 19 22 21 15 15 20 21
South Africa 51 75 79 82 71 73 82 73
Spain 100 86 84 82 100 102 87 135
Sweden 44 46 55 61 56 43 58 60
Switzerland 75 74 76 83 71 76 84 86
Taiwan 107 125 128 130 110 87 73 62
Thailand 51 60 107 76 70 66 74 80
United Kingdom 235 310 339 357 429 419 513 392
United States 665 894 907 908 843 1,032 1,239 1,200
Other Countries 305 252 436 510 470 519 308 284
World Total 4442.1 5154.4 5386.9 5175.7 5051.8 5600.0 5627.0 5319.0

Source: International Copper Study Group, October, 2012

Source: International
(e) Estimated Copper
on partial yearStudy Group, Oct. 2012.
data (Jan-July)
e
Estimated on partial-year data (Jan.-Aug.).

Statistical Section 75

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

2005 2006 2007 2008 2009 2010 2011 2012

(e)
Australia 2.3 2.0 7.5 2.9 1.3 1.8 1.0 0.0
Austria 82.8 89.5 88.5 114.2 132.4 146.2 131.3 137.0
Belgium 257.7 297.8 319.5 253.1 217.2 274.0 255.7 295.0
Brazil 1.6 0.7 2.9 4.3 0.5 1.5 5.2 17.4
Canada 48.0 56.2 143.8 51.8 41.3 73.7 64.4 55.0
China 4821.2 4942.9 5584.6 5577.0 3998.0 4364.4 4687.3 4451.0
Czech Rep. 6.2 8.4 8.8 8.4 9.5 11.6 18.9 19.7
Denmark 14.3 8.3 9.0 16.5 10.3 9.4 9.1 8.8
Finland 2.4 1.3 2.6 2.7 7.0 89.9 8.2 10.0
France 75.4 97.8 88.3 78.3 50.3 71.9 81.3 72.8
Germany 486.1 585.2 595.7 563.6 454.8 620.4 646.8 652.6
Greece 0.9 2.1 10.2 18.6 11.2 19.5 29.3 20.5
Hong Kong 123.4 146.9 189.6 210.4 190.4 155.3 127.3 57.5
Hungary 0.4 0.6 0.4 3.1 3.9 4.0 4.7 5.6
India 150.3 103.9 105.2 103.3 78.5 92.3 153.4 74.8
Indonesia 13.4 2.3 4.0 9.7 6.6 14.2 17.2 12.6
Italy 125.3 215.7 177.5 167.2 91.5 165.2 146.4 64.1
Japan 102.9 120.8 135.7 138.7 97.1 159.4 136.8 137.6
Malaysia 23.6 12.5 26.3 13.2 8.9 13.2 18.0 12.4
Mexico 14.1 17.7 16.8 28.6 32.7 49.6 28.5 12.4
Netherlands 76.7 110.8 108.0 116.8 127.7 141.0 193.9 210.0
New Zealand 0.5 0.4 0.6 0.9 1.0 1.4 1.6 0.0
Norway 12.4 12.8 13.5 11.2 10.0 9.9 12.5 0.0
Poland 5.7 14.6 16.8 18.1 21.9 24.3 26.2 50.0
Portugal 3.3 6.0 7.9 8.8 6.8 8.5 8.0 5.8
Rep. of Korea 205.9 205.3 221.1 216.8 163.1 203.0 263.3 312.0
Singapore 15.9 18.0 7.9 4.4 2.3 3.6 7.5 18.0
Slovakia 20.0 18.0 17.5 18.0 29.1 39.8 30.7 37.0
South Africa 2.1 2.1 2.6 2.5 1.3 1.2 1.4 2.0
Spain 84.8 86.5 56.1 63.2 68.1 82.9 89.5 87.0
Sweden 51.0 55.8 80.9 92.1 97.0 108.4 121.1 118.0
Switzerland 9.8 7.6 8.0 5.3 2.7 6.1 4.2 2.2
Taiwan 112.3 145.9 130.9 106.6 70.2 90.3 89.7 93.0
Thailand 5.0 6.4 7.6 9.2 9.4 10.3 9.7 13.0
United Kingdom 41.1 19.7 23.7 22.0 18.0 27.6 29.0 29.0
United States 113.8 117.5 133.1 106.3 71.8 95.8 109.8 105.8
Other countries 111.8 50.3 79.9 77.4 74.5 155.0 98.5 261.4
World 7224.4 7590.4 8433.2 8245.3 6218.3 7228.5 7667.8 7462.0

Source: International Copper Study Group,October, 2012 and U.S. Geological Survey.
(e) : Estimate based on partial year data ( 7 months)
Source: International Copper Study Group, Nov. 2012, and U.S. Geological Survey.
e
Estimated on partial year data (8 months).

Statistical Information 76

Statistical Information 72
 (thousand metric tons)

Table 5. World Production of Copper and Copper Alloy Ingots1

(thousand metric tons)

2002 2003 2004 2005 2006 2007 2008 2009 2010

2/ 2/
Austria 1.8 2.0 2.2 2.5 2.6 2.0 2.0
Denmark 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Finland 0.8 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
France 12.5 12.3 13.0 11.4 12.5 11.0 9.9 9.9 9.9
Germany 56.1 43.7 44.1 53.6 57.2 53.6 41.7 30.7 35.1
Italy 103.3 96.5 95.0 89.0 91.8 83.4 76.9 52.7 60.6
Japan 86.6 90.0 86.2 85.4 89.7 90.5 94.2 81.4 81.9
Kazakhstan 1.1 1.6 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Mexico 52.0 52.8 0.0 0.0 0.0 0.0 0.0 0.0 0.0
2/ 2/
Netherlands 2.3 2.4 2.4 2.6 2.7 2.1 2.7
Poland 13.6 14.4 13.4 12.1 11.2 11.3 10.5 7.5 6.5
Portugal 4.5 5.3 6.0 6.7 6.8 7.0 7.4 0.0 0.0
Romania 2.9 3.7 2.7 2.2 0.0 0.0 0.0 0.0 0.0
Spain 13.3 15.5 16.8 15.6 16.7 14.1 15.2 14.3 17.2
Scandinavia 11.0 9.3 9.0 8.7 8.7 6.4 6.3 0.0 0.0
Turkey 0.0 0.0 11.4 18.5 17.5 16.6 17.1 22.6 26.2
United Kingdom 2/ 34.5 32.5 34.5 27.0 22.8 22.1 23.7 20.1 20.2
United States 123.1 114.0 122.1 122.3 120.3 118.3 118.2 96.5 100.5
World 517.5 494.4 455.8 457.6 460.5 438.4 426.3 333.6 333.5

Europe 255.8 237.6 236.1 231.4 233.0 213.0 196.3 137.2 151.5
Mid East & Asia 86.6 90.0 97.6 103.9 107.2 107.1 111.3 104.0 108.1
America 175.1 166.8 122.1 122.3 120.3 118.3 118.2 96.5 100.5

Source: International Copper Study Group. United States - USGS Minerals Yearbook, var. issues.
1/ Master Alloys not included.
2/
Data aggregated in 2009 - U.K., Netherlands and Austria.

Statistical Information 77
73 Statistical Information
 Table 5A. World Copper Alloy Foundry Production
(thousand metric tons, gross weight)
Table 5A. World Copper Alloy Foundry Production

(thousand metric tons, gross weight)

2001 2002 2003 2004 2005 2006 2007 2008 2009 2010
Argentina 0.0 2.9 3.4 3.9 0.0 0.0 0.0 0.0 0.0 0.0
Austria 3.2 3.3 3.4 3.3 5.5 2.7 0.0 0.0 2.2 2.3
Belgium 0.5 0.5 0.5 0.5 0.5 1.0 0.0 0.0 0.0 0.0
Brazil 14.1 13.7 0.0 19.5 19.0 20.3 19.8 19.9 12.1 16.5
Canada 0.0 0.0 0.0 18.6 18.6 18.6 18.6 17.7 17.7 12.1
China 125.0 137.2 157.0 327.6 416.1 470.2 571.3 600.0 600.0 700.0
Croatia 0.7 0.6 0.7 0.7 1.1 0.8 0.7 0.5 0.5 0.5
Czech Rep. 1.5 1.8 1.5 1.1 1.7 1.8 1.8 2.7 0.9 4.5
Denmark 1.1 1.3 1.6 1.3 1.1 0.8 0.8 1.4 1.4 1.4
Finland 3.8 3.9 3.8 4.0 4.0 4.3 3.5 4.6 3.1 3.9
France 25.9 29.4 28.3 27.2 26.3 25.5 25.4 24.7 18.8 19.4
Germany 88.5 90.0 91.3 88.5 84.4 98.1 96.6 94.6 76.7 77.2
Hungary 2.7 2.3 1.9 2.1 2.1 4.3 1.8 1.9 1.4 1.3
Iran 25.0 0.0 27.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Italy 114.5 110.0 106.1 97.8 83.0 92.0 86.7 81.0 59.9 69.0
Japan 86.6 86.7 100.6 105.5 97.8 105.9 106.9 98.8 75.3 79.3
Rep. Of Korea 20.8 21.6 22.2 22.9 23.2 23.6 23.9 24.1 24.5 25.1
Mexico 80.0 175.0 175.0 180.0 180.0 0.0 0.0 202.4 126.5 140.7
Netherlands 2.8 2.7 2.5 2.4 1.9 0.0 0.0 0.0 0.0 0.1
Norway 3.4 3.5 2.6 2.7 4.7 5.3 5.0 3.3 2.2 1.8
Poland 17.2 16.8 6.3 7.4 6.3 7.3 7.0 8.2 0.0 7.9
Portugal 6.0 6.6 6.0 7.8 8.7 10.8 11.1 11.4 10.8 12.7
Romania 9.8 10.0 10.0 4.1 2.7 3.4 3.8 3.5 1.8 5.5
Russian Fed. 0.0 0.0 0.0 0.0 160.0 160.0 200.0 200.0 90.0 90.0
Slovenia 3.4 3.5 3.0 0.0 6.7 0.0 7.8 0.0 3.0 1.0
South Africa 0.0 0.0 14.5 14.9 14.9 3.0 3.0 3.0 17.2 16.7
Spain 13.1 13.0 6.3 7.9 7.9 9.1 9.3 9.5 6.8 7.8
Sweden 10.6 10.0 10.9 12.0 11.2 11.9 12.5 12.5 8.4 9.6
Switzerland 2.5 2.3 2.4 3.0 2.7 3.1 3.1 2.3 1.8 2.2
Taiwan 50.0 49.0 46.4 41.8 42.0 40.9 41.3 35.6 33.2 36.5
Thailand 0.0 0.0 0.0 0.0 28.6 28.6 28.6 28.6 28.6 28.6
Turkey 2.8 2.1 2.8 8.5 16.0 17.5 19.0 16.0 12.5 12.0
Ukraine 21.0 11.0 0.0 11.0 11.0 11.0 11.0 11.0 0.0 0.0
United Kingdom 25.5 20.5 15.0 15.7 15.0 13.0 13.0 12.0 8.0 9.5
United States 252.5 254.1 246.0 235.3 234.5 209.8 197.4 190.3 174.5 194.0
1/

World 1017.0 1087.6 1113.2 1279.0 1539.2 1402.0 1528.1 1719.6 1418.4 1584.0

Europe 2/ 360.25 345.30 317.00 315.10 463.00 463.60 498.40 482.60 296.30 322.60
Mid East & Asia 310.20 296.60 356.00 506.60 624.00 686.70 790.90 803.10 774.10 881.40
America 346.55 445.73 440.19 457.29 452.13 248.70 235.80 430.90 330.80 363.30

Data Source: International Copper Study Group Bulletin, Table 18. February 2011
1/
Source: U.S. Geological Survey, Minerals Yearbook, Table 12. Consumption of raw materials at foundrys
2/
Includes Russian Federation.

Statistical Information 74
Table 5B. World Copper, Copper Alloy and Master Alloy Ingot Imports1 (thousand metric tons)

2005 2006 2007 2008 2009 2010 2011 2012 (e)

Australia 2.9 4.1 4.5 2.6 5.1 2.6 4.8 0.0
Austria 2.3 2.9 2.5 2.2 1.7 1.5 1.5 2.8
Canada 14.5 12.4 10.5 12.3 4.9 5.7 4.7 4.8
China 63.6 54.8 59.8 48.2 53.0 60.8 39.8 65.7
Finland 3.2 4.0 4.2 3.2 2.3 2.7 2.5 2.0
France 10.1 11.0 14.3 8.9 8.0 9.3 9.1 9.3
Germany 28.8 38.9 47.7 40.1 38.4 36.2 35.3 36.6
Hong Kong 7.6 7.7 4.6 2.5 2.8 1.4 0.1 1.4
India 6.3 3.2 3.6 4.3 3.6 0.9 4.1 5.3
Italy 8.1 15.2 25.1 18.5 8.2 14.7 15.9 14.8
Japan 3.8 3.2 3.0 2.9 1.1 2.4 5.4 6.0
Mexico 6.3 6.8 6.6 8.2 7.4 3.7 8.8 8.8
Poland 3.2 4.1 4.1 3.2 2.3 2.5 2.9 3.5
Portugal 4.5 5.7 4.1 4.3 3.8 3.9 4.4 4.3

Table 5C. World Copper, Copper Alloy and Master Alloy Ingot Exports1 (thousand metric tons)

2005 2006 2007 2008 2009 2010 2011 2012

(e)
Australia 4.6 5.0 4.9 5.2 4.2 6.0 6.3 0.0
Belgium 14.5 13.4 14.8 12.7 9.5 12.1 11.8 14.8
Canada 3.5 7.5 6.3 4.6 2.0 2.9 2.7 3.7
France 9.9 9.7 13.1 13.1 9.4 13.6 10.6 11.6
Germany 21.0 23.4 20.9 16.5 9.8 12.2 12.3 15.3
Hong Kong 11.1 11.0 9.0 3.2 2.6 1.9 1.0 1.6
Italy 14.2 15.3 21.0 15.3 12.8 15.6 20.0 22.7
India 12.4 10.6 11.2 7.1 3.6 1.4 2.3 0.0
Japan 29.9 33.9 33.1 32.8 31.8 25.5 21.8 24.4
Netherlands 3.0 5.7 5.7 6.4 4.0 3.2 3.9 1.6
Poland 6.2 6.2 6.4 4.9 2.4 1.1 1.3 1.3
Rep. of Korea 20.2 20.6 17.7 17.1 15.2 20.7 21.2 23.2
Russian Fed. 7.8 7.2 5.4 4.6 9.9 4.8 0.9 2.8
Singapore 8.1 7.5 6.9 7.7 7.3 2.5 5.8 6.1
South Africa 5.0 4.4 27.0 2.5 1.3 0.6 2.6 2.3
Spain 9.8 10.7 12.6 11.9 12.0 15.9 16.0 20.3
Sweden 5.3 6.4 8.8 5.6 3.3 8.6 5.6 4.0
Switzerland 0.9 0.9 0.8 1.1 0.5 0.3 1.0 0.9
Taiwan 7.3 10.1 7.9 6.0 6.7 4.1 4.9 4.1
Turkey 2.2 0.0 5.6 6.9 2.3 3.6 10.1 7.6
Ukraine 7.8 12.4 19.8 11.2 7.0 2.0 0.0 0.0
United
Kingdom 15.0 17.2 18.1 17.7 11.3 12.7 16.9 15.9
United States 35.4 40.1 40.4 38.9 27.6 36.2 35.7 34.8
Rest of World 63.8 84.6 114.6 96.2 51.5 37.8 95.0 54.9
World Total 318.7 363.8 413.8 349.2 248.1 245.3 309.9 273.6

1
Data includes both copper alloy and master alloy ingots. Source: ICSG Monthly Bulletin, Oct. 2012. e
Estimated on 7 months data.

75 Statistical Information
Table 6. U.S. And World Refined Copper Consumption and U.S. Copper from Scrap
Table 6.
(Metric tons, copper)
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 15,185,000 3,022,654 7 358,392 27 73 1,310,000 4,099,105 32 23
2001 15,014,300 2,620,322 7 316,617 28 72 1,150,000 3,123,572 37 27
2002 15,210,000 2,365,194 3 208,219 20 80 1,029,622 3,298,121 31 25
2003 15,717,100 2,295,300 2 206,053 22 78 944,337 3,361,546 28 22
2004 16,832,700 2,414,800 2 191,210 20 80 965,094 3,431,398 28 23
2005 16,683,300 2,274,000 2 182,499 19 81 952,503 3,191,319 30 24
2006 17,034,400 2,110,000 2 151,000 16 84 968,499 3,010,356 32 27
2007 18,196,600 2,137,000 2 158,000 17 83 933,000 3,032,253 31 25
2008 18,053,100 2,020,000 3 156,000 18 82 859,000 2,696,100 32 26
2009 18,070,200 1,650,000 3 138,000 18 82 777,000 2,236,893 35 29
2010 19,346,400 1,760,000 2 143,000 18 83 785,000 2,418,800 32 27
2011 19,864,500 1,761,000 2 153,000 17 83 802,000 2,400,700 33 27
2012 e/ 20,522,000 1,793,000 2 150,000 17 83 786,320 2,050,320 38 31

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

Statistical Information 76
Table 6A. U.S.
Table 6A. Cumulative Copper Calculations,
U.S. Cumulative 1955-2012
Copper Calculations, 1955–2012
(Metric Tons, Copper Content)
(metric tons, copper content)
Annual Statistics 1 Resource Calculations 4 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, 1906-2009 Primary plus net exports less New Scrap
1955 1,626,799 466,823 1,159,976 #REF! 29,915,218 22,575,374 #REF! 12,897,499 43.1
1956 1,641,023 425,006 1,216,017 #REF! 30,662,288 23,419,658 #REF! 13,322,505 43.4
1957 1,451,195 403,237 1,047,958 #REF! 31,350,319 24,183,405 #REF! 13,725,742 43.8
1958 1,304,939 373,186 931,753 #REF! 31,932,028 24,906,783 #REF! 14,098,928 44.2
1959 1,547,231 427,291 1,119,940 #REF! 32,634,526 25,750,982 #REF! 14,526,219 44.5
1960 1,452,182 389,514 1,062,668 #REF! 33,296,124 26,541,492 #REF! 15,041,122 45.2
1961 1,517,154 372,953 1,144,201 #REF! 34,043,174 27,311,637 #REF! 15,528,785 45.6
1962 1,639,881 377,093 1,262,788 #REF! 34,846,958 28,147,906 #REF! 15,938,552 45.7
1963 1,712,345 382,690 1,329,655 #REF! 35,675,090 29,031,891 #REF! 16,355,766 45.8
1964 1,776,341 429,571 1,346,770 #REF! 36,460,395 30,023,463 #REF! 16,872,279 46.3
1965 1,981,932 465,781 1,516,151 #REF! 37,305,040 31,160,393 #REF! 17,388,022 46.6
1966 2,216,369 485,217 1,731,152 #REF! 38,310,863 32,370,804 #REF! 17,894,957 46.7
1967 1,835,788 437,861 1,397,927 #REF! 39,094,184 33,423,054 #REF! 18,378,479 47.0
1968 1,909,069 472,436 1,436,633 #REF! 39,898,102 34,528,314 #REF! 18,931,537 47.4
1969 2,058,319 521,531 1,536,788 #REF! 40,709,177 35,776,141 #REF! 19,509,294 47.9
1970 1,818,866 457,286 1,361,580 #REF! 41,396,092 36,907,947 #REF! 20,043,030 48.4
1971 1,886,418 403,812 1,482,606 #REF! 42,192,010 37,996,678 #REF! 20,496,343 48.6
1972 2,142,445 415,667 1,726,778 #REF! 43,152,220 39,176,901 #REF! 20,950,635 48.6
1973 2,223,351 441,086 1,782,265 #REF! 44,126,162 40,426,237 #REF! 21,470,476 48.7
1974 2,144,892 438,562 1,706,330 #REF! 45,041,942 41,645,784 #REF! 21,978,496 48.8
1975 1,473,444 334,908 1,138,536 #REF! 45,633,001 42,527,536 #REF! 22,394,379 49.1
1976 1,923,872 380,225 1,543,647 #REF! 46,518,134 43,566,511 #REF! 22,827,177 49.1
1977 2,069,701 409,928 1,659,773 #REF! 47,516,417 44,651,936 #REF! 23,293,894 49.0
1978 2,369,537 501,650 1,867,887 #REF! 48,647,169 45,899,171 #REF! 23,885,326 49.1
1979 2,434,234 604,301 1,829,933 #REF! 49,528,785 47,451,696 #REF! 24,590,717 49.6
1980 2,178,849 613,458 1,565,391 #REF! 50,270,463 48,889,123 #REF! 25,319,992 50.4
1981 2,271,416 591,805 1,679,611 #REF! 51,134,116 50,296,520 #REF! 25,989,194 50.8
1982 1,762,385 517,726 1,244,659 #REF! 51,709,035 51,483,986 #REF! 26,585,582 51.4
1983 2,012,739 449,478 1,563,261 #REF! 52,662,949 52,567,565 #REF! 27,101,892 51.5
1984 2,116,058 460,695 1,655,363 #REF! 53,655,093 53,687,479 #REF! 27,679,845 51.6
1985 2,144,436 503,407 1,641,029 #REF! 54,660,443 54,826,563 #REF! 28,350,784 51.9
1986 2,138,223 477,469 1,660,754 #REF! 55,669,897 55,953,091 #REF! 29,004,126 52.1
1987 2,196,540 497,937 1,698,603 #REF! 56,652,718 57,167,150 #REF! 29,665,031 52.4
1988 2,213,768 518,179 1,695,589 #REF! 57,560,996 58,474,041 #REF! 30,359,678 52.7
1989 2,184,534 547,561 1,636,973 #REF! 58,436,904 59,782,496 #REF! 31,111,624 53.2
1990 2,168,179 535,656 1,632,523 #REF! 59,295,555 61,092,025 #REF! 31,800,027 53.6
1991 2,090,000 518,000 1,572,000 #REF! 60,177,412 62,292,715 #REF! 32,473,337 54.0
1992 2,300,000 555,000 1,745,000 #REF! 61,205,578 63,569,792 #REF! 33,098,069 54.1
1993 2,510,000 543,000 1,967,000 #REF! 62,433,501 64,855,487 #REF! 33,703,793 54.0
1994 2,690,000 500,000 2,190,000 #REF! 63,790,004 66,183,384 #REF! 34,358,907 53.9
1995 2,540,000 442,509 2,097,491 #REF! 65,010,718 67,500,179 #REF! 35,034,133 53.9
1996 2,830,000 428,362 2,401,638 #REF! 66,519,028 68,819,331 #REF! 35,608,661 53.5
1997 2,950,000 497,670 2,452,330 #REF! 67,992,502 70,283,927 #REF! 36,246,330 53.3
1998 3,027,355 465,894 2,561,461 #REF! 69,555,373 71,706,150 #REF! 36,831,273 53.0
1999 3,127,206 380,936 2,746,270 #REF! 71,275,683 73,034,756 #REF! 37,366,834 52.4
2000 3,090,537 358,392 2,732,145 #REF! 73,105,750 74,347,756 #REF! 38,026,342 52.0
2001 2,508,768 317,212 2,191,556 #REF! 74,246,084 75,497,981 #REF! 38,710,326 52.1
2002 2,610,866 190,135 2,420,731 #REF! 75,673,696 76,528,203 #REF! 39,247,783 51.9
2003 2,427,975 206,842 2,221,133 #REF! 77,353,824 77,472,432 #REF! 39,968,339 51.7
2004 2,554,431 191,210 2,363,221 #REF! 79,046,244 78,437,526 #REF! 40,684,629 51.5
2005 2,387,306 182,499 2,204,807 #REF! 80,515,056 79,390,029 #REF! 41,353,044 51.4
2006 2,192,857 151,000 2,041,857 #REF! 80,515,056 80,358,528 #REF! 42,102,421 52.3
2007 2,272,504 162,000 2,110,504 #REF! 81,739,478 81,291,528 #REF! 42,897,175 52.5
2008 1,996,100 159,000 1,837,100 #REF! 81,853,560 82,150,526 #REF! 43,702,268 53.4
2009 1,597,893 138,000 1,459,893 #REF! 82,876,578 82,927,528 #REF! 44,459,171 53.6
2010 1,776,800 143,000 1,633,800 #REF! 82,674,453 83,712,528 #REF! 45,365,722 54.9
2011 1,751,700 153,000 1,598,700 #REF! 83,868,378 84,514,526 #REF! 46,463,615 55.4
2012 1,414,000 150,000 1,264,000 #REF! 83,624,153 85,300,848 #REF! 47,529,207 56.8

1
Annual
1/ AnnualStatistics fromU.S.
Statistics from U.S. Bureau
Bureau of Mines,
of Mines, U.S. Geological
U.S. Geological Survey. Survey. 2e/
Consumption
estimated on = primary
partial yearrefined
data. production + old=scrap
3/ Primary copper + net imports
consumption + stock change
less old scrap.
3
Primary copper = consumption less old scrap. 4
Series based onchange
2/ Consumption = primary refined production + old scrap + net imports+stock 1864-2012 data. e Estimated
4/ Serieson partial
based year data.
on 1864-2012 data

77 Statistical Information
Statistical Information 81
Table 6B. Estimation of the Recycling Input Ratio (RIR) and Recovery Ratio for the United States
1981 - 2011
(Thousand Metric Tons)

Table 6B. Estimation of the Recycling Input Ratio (RIR)1 and Recovery Ratio
for the United States2, 1981–2011 (thousand metric tons)
Brass & Wire Foundry Total Gross Weight Recycling Copper Scrap Total Scrap Recycling
Year Mill Production Semis Scrap Input Ratio Exports Recovered Recovery Ratio
3/

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 3208.2 234.5 3442.7 1148.1 33.3 657.9 1806.0 52.5
2006 3061.1 209.8 3270.9 1150.1 35.2 803.1 1953.2 59.7
2007 2946.9 197.4 3144.3 1079.8 34.3 906.5 1986.3 63.2
2008 2670.2 190.9 2846.3 997.6 35.0 908.1 1905.7 67.0
2009 2043.9 174.5 2218.4 914.3 41.2 842.6 1756.9 79.2
2010 1934.2 194.0 2128.2 930.2 43.7 1033.0 1963.2 92.2
2011 2181.4 199.8 2381.2 942.3 39.6 1239.3 2181.6 91.6

p/
preliminary
1/
Recycling Input Ratio (RIR) = Total Scrap Consumed/Total Semis Produced
methodology after ICSG Special Paper, 2004 , "Recycling in Western Europe"
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.

Statistical Information 78
 Table 7 U. S. Production of Refined Copper, by Source
Table 7. metric
(thousand U.S.tons)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 702 46 504 1,252 3
2008 603 54 507 1,164 4
2009 558 46 476 1,080 4
2010 608 18 430 1,054 3
2011 545 37 449 1,031 4
2012 e/ 435 38 469 942 4

Data : U.S. Bureau of Mines and U.S. Geological Survey e/ Estimated on partial years data.
Statistical Information 83

79 Statistical Information
 Table 8. U.S. Exports and Imports of Copper and Copper Alloy Scrap
able 8. U.S. Trade in Copper
(metricand Copper Alloy Scrap
tons)
etric 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
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 79,776 388,689 279,856 325,118 713,807 604,974
2005 30,067 83,700 60,264 113,767 90,331 291,481 209,866 366,381 657,862 576,247
2006 24,927 92,598 66,671 117,525 91,598 404,091 290,946 399,029 803,120 689,975
2007 58,293 74,781 53,842 133,074 112,135 577,184 415,572 329,327 906,511 744,899
2008 32,785 73,547 52,954 106,332 85,739 629,638 453,339 278,493 908,131 731,832
2009 16,299 55,534 39,984 71,833 56,283 597,811 430,424 244,762 842,573 675,186
2010 21,380 74,459 53,610 95,839 74,990 701,447 505,042 333,539 1,034,986 838,581
2011 30,359 79,444 57,197 109,803 87,556 738,730 531,886 500,563 1,239,293 1,032,449
2012 e/ 29,860 75,356 54,256 105,216 84,116 716,114 515,602 484,106 1,200,220 999,708

Sources:
Sources: U.S.
Dept. of Dept. of Commerce,
Commerce,USITC U.S.U.Bureau
trade data base, S. Bureauof
of Mines and
Mines and U.S.
U. S. Geological
Geological Survey Survey.
e
Estimated on partial
e/ Estimated year
on partial yeardata.
data. January-October

1/
Table 8A. US Domestic Exports of Copper and Copper Alloy Scrap
(metric tons)
Table 8A. U.S. Domestic Exports of Copper and Copper Alloy Scrap1
tistical Information (metric tons) 84

Type of Scrap 2006 2007 2008 2009 2010 2011

No 1 67,319 47,834 63,711 66,574 64,644 119,327

No 2 and nonspecified 331,710 281,493 214,782 178,188 268,895 381,234
Total unalloyed scrap: 399,029 329,327 278,493 244,762 333,539 500,561
Red, SemiRed Brass >0.3%Pb 4,952 6,898 5,298 6,425 4,964 4,234
Red Brass < 0.3%Pb 24,940 22,568 26,565 41,568 36,619 41,207
Yellow Brass > 0.3% Pb 57,054 73,540 59,436 30,414 26,653 41,668
Yellow Brass < 0.3% Pb 35,384 28,609 29,605 21,408 41,190 59,215
Other copper scrap nesoi 85,490 96,291 105,590 116,040 198,244 165,224
Mixed copper & copper alloy 196,271 349,278 403,144 381,956 391,777 427,182
Total alloy & mixed scrap: 404,091 577,184 629,638 597,811 699,447 738,730

Grand Total Scrap Exports: 803,120 906,511 908,131 842,573 1,032,986 1,239,291

Data does not include reexports

1Sources: USITC data webb, 2012, US Dept of Commerce.
e

/ Source: USITC data webb, Dec. 2012, US Dept of Commerce.

Data does not include reexports.
Statisticale/Information
Estimate based on Jan-October exports 80
 Table 9.Table
U.S. Trade
9. U.S. and
Trade Consumption
and Consumption ofof Copper
Copper AshAsh and 1/Residues
Residues
1
and Zinc
, and Zinc products Products
from Scrap
from Scrap. (thousand metric(Thousand
tons) Metric Tons)

Product 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011

Exports:
Copper Ash & Residues (Gross Wt) 12.27 23.36 28.11 21.15 25.87 11.42 14.00 12.99 8.34 2.95 7.08 19.04 20.84 50.81 62.15 46.18 40.92 43.96 38.30
Zinc Dross, Skimmings, Residues (262019)
Zinc Content of Dross, etc. 12.10 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 14.14 10.36 6.91 9.35 15.46

Imports:
2
Copper Ash & Residues 1.55 1.06 1.74 1.68 0.49 1.20 0.66 0.76 0.63 0.70 1.00 1.47 1.59 1.67 1.63 1.10 0.74 0.84 0.00
Zinc Content of Product:
Zinc Dross & Skimmings (26201930) 13.62 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 16.90 13.98 10.28 11.13 9.72
Zinc Ash and Residues (26201960) 1.25 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 0.73 0.08 0.02 1.43 0.19
Total Zinc in Dross, etc. 14.87 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 17.62 14.06 10.30 12.56 9.90

Zinc Recovered from Scrap:

Zinc Recovered as Pb-free Zinc Oxide 36.00 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/ 15.0 e/ 15.0 e/ 15.0 e/ 15.0 e/ 15.0 e/
Zinc Recovered from All Scrap 355.00 361.00 353.00 379.00 374.00 434.00 399.00 439.00 368.00 366.00 345.00 349.00 368.43 346.52 234.00 339.00 273.00 331.00 330.00
3
Zinc Recovered in Copper Alloys 153.76 172.68 169.63 179.63 193.97 201.00 206.70 223.00 205.00 198.00 176.00 168.00 176.00 159.00 149.20 130.02 119.29 124.80 124.00

Purchased Copper-base Scrap:

Lowgrade Copper Ash, Residues, etc.
Gross Weight Scrap 161.31 81.40 92.60 83.10 87.10 124.00 111.00 105.00 70.24 30.20 32.16 35.26 34.96 35.20 23.50 23.30 23.30 23.00 22.90
4
Copper Content 56.46 28.49 32.41 29.09 30.49 43.40 38.85 36.75 24.58 10.57 11.25 12.34 12.23 12.32 8.23 8.16 8.16 8.05 8.02

Low Grade Copper Base Shipments 5

Copper Content of Shipments 59.21 35.61 40.50 34.81 39.05 46.20 43.09 40.54 26.87 10.90 12.73 17.54 17.94 28.43 28.35 23.21 21.74 22.60 21.42
4
Gross Weight of Shipments 169.16 101.73 115.72 99.46 111.56 131.99 123.11 115.82 76.78 31.14 36.39 50.11 51.25 81.23 80.99 66.33 62.12 64.56 61.20

Data sources:
Data sources: USGS, USBM
USGS, Minerals
USBM Yearbooks
Minerals and Mineraland
Yearbooks Industry Surveys,
Mineral BureauSurveys,
Industry of Census Bureau
Trade Data.
of Census Trade Data.
NA = not available
NA = not available
1/
Skimmings, drosses, ashes & residues containing 20-65% copper
Skimmings,
12/
drosses,
Reported in copper ashes
content and residues
of material shipped. containing 20-65% copper
23/ Composition of secondary copper alloy production; 96% from scrap, 4% from other
Reported in copper content of material shipped.
4/
3 Assumption of 35% copper. USGS published series is gross weight.
Composition of secondary copper alloy production; 96% from scrap, 4% from other.
5/
4 Calculated shipments of low-grade ashes and residues from domestic producers.
Assumption of 35% copper. USGS published series is gross weight.
5 ( Consumption plus total exports minus imports of low grade ash and residues.)
Calculated shipments of low-grade ashes and residues from domestic producers.
(Consumption plus total exports minus imports of low grade ash and residues.)

atistical Information 86

81 Statistical Information
Table 10. Ingots, Foundry Castings, Brass and Wire Mill Semis and Copper Sulfate Production in the United States
thousand metric tons)
Table 10. Ingots, Foundry Castings, Brass- and Wire-Mill Semis and Copper Sulfate
Production in the United States (thousand metric tons)
Type of
Product 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011
Alloy Ingots:
Leaded & semi-red brass 103.0 87.1 88.6 64.7 68.4 68.7 69.4 65.3 65.3 52.4 51.4 51.2
Yellow Brass 5.7 6.0 4.7 4.4 5.9 5.9 5.6 5.6 5.6 4.9 5.1 5.3
Tin & High Leaded Tin Bronze 27.8 25.3 23.8 18.7 20.6 20.6 20.2 19.5 19.5 14.2 16.6 18.7
Nickel Silver 2.3 2.5 1.9 2.3 2.1 2.0 2.1 1.6 1.6 1.1 1.0 1.0
Aluminum & Manganese Bronze13.9 16.6 13.8 12.9 14.3 14.2 14.0 14.4 14.3 13.1 13.8 13.8
Other Alloy Ingots 8.2 8.4 7.6 10.3 10.8 10.9 9.1 12.0 12.0 10.8 12.6 12.5
Hardeners and Master Alloys 13.8 11.3 5.4 5.4 5.5 5.8 7.6 7.7 7.7 7.7 7.7 5.3

Total Ingots 174.6 157.1 128.6 118.6 127.6 128.1 128.0 126.0 125.8 104.1 108.2 107.8

278.3 252.5 254.1 246.0 235.3 234.5 209.8 197.4 190.9 174.5 194.0 199.8
2/
Foundry Castings

Copper Sulfate (Gross Weight) 55.5 55.2 49.2 32.1 25.1 25.6 19.5 22.6 22.0 22.4 23.7 22.8

Copper & Copper Alloy Powder 7.7 7.6 7.6 6.9 0.1 0.4 0.2 1.3 1.1 0.6 0.0 0.0
1/

Total Semifabricates 3,916.5 3,306.2 3,257.2 3,075.4 3,435.6 3,208.2 3,061.1 2,946.9 2,670.2 2,043.9 1,934.2 2,181.4
Copper Semis 3,012.5 2,634.9 2,532.6 2,404.4 2,708.1 2,514.1 2,359.1 2,328.5 2,115.4 1,634.1 1,612.3 1,709.0
Copper Alloy Semis 904.0 671.3 724.6 671.0 727.5 694.1 702.0 618.4 554.8 409.8 321.9 472.4

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

Table
Table 10A. 10a.
Exports ofU.S. Exports
Copper ofAlloy
and Copper Copper andCopper
Semis, and Copper Alloy
Sulfate, Semis,
Powder and
and Copper Copper
Hydroxides Sulfate,

(thousand metric tons) Powder and Hydroxides (Thousand metric tons)

2004 2005 2006 2007 2008 2009 2010 2011 20121/

Total Copper Semis Exports 205.50 221.80 233.80 224.10 200.40 170.90 204.30 195.10 206.00
Total Copper Alloy Semis Exports 91.60 104.30 99.90 90.70 82.40 57.40 68.00 63.70 64.00
Total Semis Exports 297.20 326.20 333.80 314.80 282.80 228.30 272.30 258.70 270.00

283325 - Copper Sulphate (G.W.) Exports 1.44 3.22 3.29 4.77 5.43 5.88 7.97 6.52 6.49
Copper Sulphate (Copper Content) 0.56 1.25 1.28 1.86 2.12 2.29 3.10 2.54 2.53
74061 - Copper Powder Non-Lamellar Structure 8.29 10.82 10.44 9.92 7.38 5.81 9.10 7.54 7.47
74062 - Copper Powder Flakes Exports 0.90 1.43 1.03 1.35 1.32 0.63 1.00 0.68 1.16
7406 - Total Copper Powder Exports 9.18 12.25 11.47 11.27 8.70 6.44 10.10 8.22 8.63
2825503 - Copper Oxides & Hydroxides Exports 20.70 19.63 21.71 21.95 26.76 22.46 27.66 26.32 23.13
Table 10B. US Imports of Copper and Copper Alloy Semis, and Copper Sulfate, Powder and Copper Hydroxides
Table 10b.
(Thousand metric tons)
U.S. Imports of Copper and Copper Alloy Semis, and Copper Sulfate,
1/ Based on 10 months data. Source U.S. Dept of Commerce and the U.S. International Trade Commission.
Powder and Hydroxides (Thousand metric tons)
Major export destinations in 2009 and 2010 were:
Hydroxides/oxides:
2004 China, Canada,
2005 Korea, Sweden,
2006 2007 Singapore,
2008 Portugal and
2009United Kingdom.
2010 2011 2012 1/
Copper sulfate : Canada, Israel, Ireland and China.
Total Copper Semis Imports 423.60 554.30 562.00 409.40 340.10 250.30 245.10 273.00 265.00
Total Copper Alloys Semis Imports 146.60 117.30 114.60 98.10 99.80 63.40 95.40 97.20 104.00
Total Semis Imports 570.10 671.60 676.60 507.50 439.90 313.80 340.50 370.10 369.00

283325 - Copper Sulphate (G.W.) Imports 56.05 55.85 53.61 57.01 56.77 49.34 47.98 38.61 38.36
Copper Sulphate (Copper Content) 21.84 21.77 20.89 22.22 22.12 19.23 18.70 15.05 14.95

2825503 - Copper Hydroxides Imports 3.75 3.00 1.45 0.43 0.41 0.25 0.24 0.75 0.42
74062 - Copper Powder Flakes Imports 0.79 0.91 1.57 0.79 0.99 0.63 0.67 0.88 0.75
74061 - Copper Powder Non-Lamellar Structure Imports 2.02 2.81 3.02 3.65 2.61 2.38 3.19 3.29 2.86
7406 - Total Copper Powder Imports 2.82 3.72 4.59 4.44 3.60 3.01 3.86 4.18 3.61
Based on 8 months data. Source U.S. Dept of Commerce and the U.S. International Trade Commission.
1/
1/ Based on 10 months data. Source U. S. Dept of Commerce and the U.S. International Trade Commission.
Major export destinations in 2009 and 2010 were:
Hyrdroxides/oxides: China, Canada, Korea, Sweden, Singapore, Portugal and United Kingdom.
Major import sources in 2009 and 2010
Copper sulfate : Canada, Israel, Ireland and China.
Hydroxides/oxides -- Australia, Hong Kong, Mexico, Norway and Peru

Statistical Information 82 Chile China, Russia, Germany, Taiwan, Malaysia and Peru.
Copper Sulfate -- Mexico, Canada,

Statistical Information 87
 Table 11. Standard Designations for Cast Copper Alloys
Table 11. Standard Designations for Cast Copper Alloys
Percent (range) of principal metals in cast alloys
Alloy Class UNS Range Copper Tin Lead Zinc Aluminum Nickel Other
1

2
High copper alloys 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
1/ Source:
May Copper
include Development Association Inc.
columbium.
2/May include columbium.
1
Includes beryllium copper and chromium copper.
3/Includes beryllium copper and chromium copper.
2

3 Special alloys
Special alloys include
include incramet
Incramet 8009,
8009, Incramute
Incramute 1, white
1, while tombasil
tombasil, etc. etc.

Data Source: Copper Development Association.

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

Form of Recovery 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011

Electrolytic Refined 172,474 69,923 53,281 50,761 47,208 44,800 42,100 53,800 46,400 37,700 37,300
Fire-Refined (w) (w) (w) (w) (w) (w) (w) (w) (w) (w) (w)
Copper Powder 7,452 7,439 8 48 314 134 1,240 1,070 587 1,230 1,030
Copper Castings 323 300 338 574 547 612 114 136 82 82 124
Total unalloyed 180,249 77,662 53,627 51,383 48,069 45,546 42,351 55,006 47,069 39,000 38,400

In Brass and Bronze 893,363 876,216 818,087 839,975 836,591 846,000 799,000 731,000 675,000 689,000 701,000

In Alloy Iron and Steel 506 425 974 1,017 985 792 890 677 673 731 692
In Aluminum Alloys 64,006 63,177 59,258 60,446 53,401 68,800 72,600 60,700 46,100 51,600 59,600
In Other Alloys 117 122 27 28 32 36 13 8 8 9 12

In Chemical Compounds1 11,248 12,022 12,255 12,255 12,255 8,210 5,040 5,040 5,030 5,030 5,030

Total 1,149,489 1,029,624 944,228 965,094 951,332 968,546 925,000 852,000 774,000 785,000 602,000
Statistical Information 90

Source:Source: USGS Yearbook

USGS Minerals Minerals (1999-2011),
Yearbook, Copper Chapter
Copper Chapters
1
1999-2009 reflect addition of copper sulfate and other copper chemical producers, not included in previous data.
1/ (w) Fire
1999-2009 Refined
reflect included
addition in electrolytic
of copper refined
sulfate and other total.
copper Data producers,
chemical withheld.
not included in previous data.

(w) Fire Refined included in electrolytic refined total. Data withheld.


83 Statistical Information
ble 13. List of U.S. Primary Brass and Tube Mills
Table 13. List of U.S. Primary Brass and Tube Mills
COMPANY NAME CITY STATE
1. Ampco Metal Inc. (Hdqs Switzerland) Chicago Illinois
3. Ansonia Copper & Brass Ansonia Connecticut
4. Ansonia Copper & Brass Inc. Waterbury Connecticut
5. Brush Wellman Inc. Elmore and Lorain Ohio
6. Brush Wellman Alloy Products Reading Pennsylvania
7. Cambridge Lee Industries (Grupo Iusa) Reading Pennsylvania
8. Cerro Flow Products.(Copper tube) Sauget Illinois
9. Cerro Flow Products (Copper tube) Shelbina and Mexico Missouri
10. Chase Copper & Brass (Div. Global Brass and Copper) Montpelier Ohio
11. Chicago Extruded Metals Cicero Illinois
12. CMC Howell Metal (Commercial Metals) New Market Virginia
13. Concast Metal Products Birmingham Ohio
14 Drawn Metal Tube Co. Tomaston Connecticut
15. The Electric Materials Co.(United Stars) Northeast Pennsylvania
16. Freeport McMoRan Bayway Operations Elizabeth New Jersey
17. Fushi Copperweld Bimetallics (Fushi Internat. 2007) Fayetteville Tennessee
18. Hussey Copper Ltd. Leetsdale Pennsylvania
19. Hussey Copper Ltd. Eminence Kentucky
20. Weiland Copper Products (Weiland Gp, Germany) Wheeling Illinois
21. Weiland Copper Products (Weiland Gp, Germany) Pine Hall North Carolina
22. Little Falls Alloys Paterson New Jersey
23. Luvata Grenada LLC (Heatcraft) Grenada Missouri
24. Luvata Buffalo Inc. (Nordic Capital) Buffalo New York
25. Luvata Franklin Inc. (Outukumpu) Franklin Kentucky
26. Luvata Appleton LLC (Valleycast Inc.) Appleton Wisconsin
27. MAC Metals Inc. Kearny New Jersey
28. MAC Metals Inc. (Kearney Smelting & Refining) Kearny New Jersey
29. The Miller Co. (Diehl Metall Corp., Germany) Meriden Connecticut
30 Mueller Brass Products (Rod) (Mueller Industries) Port Huron Michigan
31. Extruded Metals (Mueller Industries Brass Rod) Belding Michigan
32. Mueller Copper Tube Products Co. (Mueller Industries) Fulton Mississippi
33. Mueller Copper Tube Products Co. (Mueller Industries) Wynne Arkansas
34. National Copper Products, Inc. (Tube Mill) Dowagiac Michigan
35. National Copper & Smelting (Nat Copper Products) Huntsville Alabama
36. NGK Berylco (NGK Metals Corp.) Sweetwater Tennessee
37. Olin Corp.(Div Global Brass & Copper) E. Alton Illinois
38. Olin Corp.(Div Global Brass & Copper)(Bryan Metals) Bryan Ohio
39. Olin Corp.(Div Global Brass & Copper) Cuba Missouri
40. PMX Industries Inc. (Poongsan Corp. S.Korea) Cedar Rapids Iowa
41. Revere Copper Products Rome New York
42. Small Tube Products Inc. (Wolverine Tube) Altoona Pennsylvania
43. Winchester Olin ( Div of Global Brass and Copper) Oxford Mississippi
44. Wolverine Tube Inc. (Hdqs Huntsville, Ala) Carrolton Texas
45. Wolverine Tube Inc. Shawnee Oklahoma
46. Wolverine Joining Technologies (Wolverine Tube Inc.) Warwick Rhode Island
47. Wolverine Tube Inc. Ardmore Tennessee

Statistical Information 84
 Table14.
Table 14. List
ListofofU.S.
U.S.Ingotmakers,
Ingot makers,Secondary
SecondarySmelters
Smeltersand
andRefiners,
Refiners,and
andSecondary
SecondaryChemical
and
Hydrometallurgical Plants
Hydrometallurgical Plants
Company Name City State Remarks Status
American Nickel Alloy Mfg. Corp New York New York Cast alloys, copper anodes Operating
Atlas Pacific Corporation Altadena California Copper alloy ingots Operating
Belmont Smltg & Refg. Works, Inc Brooklyn New York Copper alloy ingots/powder Operating
Bolton Metal Products Bellefonte Pennsylvania Custom fusible alloys Operating
Brush Wellman Inc. Cleveland Ohio Beryllium Master Alloy Operating
California Metal - X Los Angeles California Copper base & copper nickel Operating
Colonial Metals Co. Columbia Pennyslvania Brass & bronze ingots Operating
Concast Metals Mars Pennsylvania Phos copper, copper anodes Operating
Federal Metal Co. Bedford Ohio Ingots, continuous cast billets Operating
H. Kramer & Co. Chicago Illinois Copper alloy ingots Operating
Handy & Harman Attleboro Maine Precious metals, copper Closed
I Schumann & Co. Bedford Ohio Copper alloy ingots, Enviro Alloy Operating
Kearny Smelting & Refining Corp. Kearny New Jersey Ingot making closed 2003 Closed 2003
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 Master alloys Operating
National Bronze & Metals Houston Texas Founded 1983, Ohio foundry Operating
National Metals Inc. Leeds Alabama Brass and Bronze ingots Operating
R. Lavin & Sons, Inc. North Chicago Illinois N. Chicago Ref. & Smelters Closed 2003
River Smelting & Refining Co. Cleveland Ohio Ohio Superfund Site Closed 2004
SIPI Metals Corp. Chicago Illinois Brass, Bronze, Master Alloys Operating
Specialloy Copper (IBC Adv.Alloys) New Madrid Missouri Copper Alloy, Be Alloy ingot Operating
Univertical Corporation Angola Indiana Phos copper, copper anodes Operating
Avril G.Z. Brass & Bronze Cincinnati Ohio Copper alloy ingots Operating
W.J. Bullock Fairfield Alabama Brass and Bronze ingots Operating

Secondary Smelters and Refiners:

Warrenton Copper LLC (AIM) 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 Flow Products E. St Louis Illinois Fire Refinery, billet casting Closed 2001
Cerro Flow Casting Co. Mexico Missouri Billet casting, uses cathode Operating
Cerro Copper Products E. St Louis Illinois Electrolytic refinery/smelter Closed, 1998
Chemetco (Concorde Metals) Alton Illinois Secondary smelter, anode Closed, 2001
Superior Essex (LS Cable Ltd) Ft Wayne Indiana Fire Refinery, cont. cast 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, Powder Operating
Encyle Texas (Div. Of Asarco) Corpus Christi Texas Processes cu-bearing waste Closed 2007
Griffin Corp.(Kocide Chemical) Several Plants GA, TX Copper Chemicals Operating
Hydromet Environmental Inc. Newman Illinois Processes cu-bearing waste Operating
Old Bridge Chemicals Inc Old Bridge New Jersey Copper Sulfate, Copper Carbonate Operating
Peninsula Copper Inc. Hubbell Michigan Copper Chemicals Operating
Phibro-Tech(4 US, 1 French Plant) Santa Fe Springs California Copper Chemicals Operating
also (Phibro Animal Health Corp) Garland Texas Copper Chemicals Operating
(Micronutrients purchased Joliet Illinois Copper Chemicals Operating
Illinois and S.C. plants in 2003) Sumter South Carolina Copper Chemicals Operating
SCM Metals Products(Gibraltar Ind) Research Triangle North Carolina Copper Powder/pastes/oxides Operating
U.S. Filter Recovery Service Vernon California Processes cu-bearing waste Operating
(Siemens Water Technologies) Minneapolis Minnesota Processes cu-bearing waste Operating

Statistical Information 93
85 Statistical Information
Table 15. Copper and Copper Alloy Scrap Types, Showing General Range in compositions
(InTable
percent15. Copper
metal content) 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
High coppers1 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
Aluminum bronze2 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
Cocks & faucets3 (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
Refinery brass4 (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:
1/
Be, Cd,Copper
Cr coppersDevelopment Association Inc. and ISRI, 1989, U.S. Bureau of Mines.
Be,
12/
Al, Cd,
Fe, Cr
Ni coppers
alloys
Al,
23/
Fe, Ni
Mixed alloys
red and yellow brass plumbing fixtures, including nickel/chrome plated. Free of zinc die cast and aluminum parts.
Mixed
34/
red iron,
Limit 5% and yellow brass
includes plumbing
copper, brassfixtures, including
and bronze nickel/chrome-plated.
alloyed metal. Free of zinc die-cast and aluminum parts.
4
Limit 5% iron,
Sources: Copperincludes copper, brass
Development Assoc.andandbronze
ISRI, alloyed metal.
1989, US Bureau of Mines

Statistical Information 86
 Table 16. Principal U.S. Scrap Source Materials for Copper
(thousand metric tons, copper)

Table 16. Principal U.S. Scrap Source Materials for Copper

(thousand metric tons, copper)
Copper from 1950 1960 1970 1980 1990 2000 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011
Type of Scrap

New Scrap:
Copper-base 440 396 664 804 751 906 802.9 700.9 735.1 729.6 773 723 659 608 612 618
Aluminum-base 6 5 10 20 23 45.5 37.14 36.45 38.76 39.31 46.7 44.4 37.7 29.4 30.1 41.7
Nickel-base 0.2 0.1 0.1 0.2 0.04 0.018 0.018 0.018 0.018 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 nil
Total 446 401 674 824 774 952 840.1 737.4 773.9 769 819 767 697 638 642 649

Old Scrap:
Copper Base 437 387 453 596 502 334 165.4 184.9 168.8 167.9 128 131 133 120 121 124
Aluminum-base 2 2 4 15 34 28.4 23.98 21.74 22.12 14.18 22.4 27.2 22.9 16.7 21.7 28.7
Nickel-base 1.00 0.50 0.70 0.10 0.08 0.17 0.148 0.213 0.279 0.214 0.197 0.275 0.275 0.267 0.267 0.267
Zinc- & tin-base 0.09 0.08 0.04 0.1 0.03 0.032 0.029 0.027 0.029 0.033 0.038 0.013 0.009 0.009 0.009 0.013
Total 440 390 458 611 536 363 189.5 206.8 191.2 182.4 151 158 156 137 143 153

Total Copper 886 791 1,132 1,435 1,310 1,310 1,030 944 965 951 969 925 852 774 785 802
Source: U.S. Bureau of Mines and U.S. Geological Survey, Minerals Yearbooks, var. issues.
Table 17A. U.S. Copper and Copper Alloy Scrap Consumption, 1977-19941
Source: U. S. Bureau of Mines and U. S. Geological Survey, Minerals Yearbooks, var. issues. Table 6
(Metric Tons)
Table 17A. U.S. Copper Scrap and Copper Alloy Consumption, 1976–19921
(metric tons)
Scrap Consumption by: 1977 1978 1979 1982 1983 1984 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994
Plant type:
Brass Mill 615,205 637,942 703,138 508,478 624,466 675,472 621,023 627,628 683,431 757,047 725,586 754,386 695,200 854,771 744,000 862,000
Secondary Smelters & Refiners 745,980 918,238 1,281,257 946,480 693,678 689,375 736,034 804,344 823,032 797,682 828,905 777,833 802,139 748,953 892,000 779,000
Foundries and misc. plants 67,238 86,799 88,831 59,889 63,472 68,610 54,722 63,037 72,173 64,507 66,097 75,654 55,680 64,800 60,700 67,000
Total, gross weight: 1,428,423 1,642,979 2,073,226 1,514,847 1,381,616 1,433,457 1,411,779 1,495,009 1,578,636 1,619,236 1,620,588 1,607,873 1,553,019 1,668,524 1,696,700 1,708,000
1
Source:
Old Scrap 555,140 664,289 830,335 659,574 574,376 572,311 570,923 612,896 675,088 644,314 673,258 696,125 696,125 731,596 741,817 669,000
New Scrap 873,283 978,690 1,242,891 855,273 807,240 861,146 840,856 882,113 903,548 974,916 943,501 856,892 856,892 936,928 954,883 1,040,000
Ratio Old/New 0.64 0.68 0.67 0.77 0.71 0.66 0.68 0.69 0.75 0.66 0.71 0.81 0.81 0.78 0.78 0.64
Type of Scrap:
Unalloyed copper:
No. 1 scrap 304,928 331,910 392,112 279,877 271,990 270,228 348,087 389,198 410,636 416,655 418,893 424,128 430,790 448,285 480,600 513,900
No. 2 scrap, mixed 262,413 326,112 447,267 417,004 324,665 367,436 278,047 338,031 383,862 409,332 392,755 342,658 335,456 380,284 385,690 361,350
Total Unalloyed: 567,341 658,022 839,379 696,881 596,655 637,664 626,134 727,229 794,498 825,987 811,648 766,786 766,246 828,569 866,290 875,250
2
Red Brass 73,452 84,052 89,427 61,264 57,277 64,496 56,196 54,592 61,222 53,638 68,448 74,954 62,126 70,151 61,400 62,340
Cartridge brass 74,601 82,852 80,520 54,057 66,534 70,781 67,221 71,549 78,461 139,074 126,224 97,726 56,068 51,619 54,300 61,100
3
Yellow and low Brass 359,569 385,836 408,392 288,327 345,638 387,165 347,074 314,405 341,347 338,949 326,167 371,656 351,351 393,268 409,560 454,850
Automobile Radiators 73,051 83,453 94,123 58,942 64,814 75,440 77,230 55,555 62,260 104,364 96,395 94,947 88,621 77,129 71,800 70,970
Bronze 24,413 23,299 24,574 18,195 20,949 24,593 19,994 20,030 21,050 21,296 21,092 18,608 20,683 25,001 23,600 23,200
Nickel silver/cupronickel 28,247 18,894 28,449 17,564 22,912 21,811 15,819 13,229 9,617 14,968 23,619 21,303 17,952 14,708 14,800 21,900
Aluminum bronze 1,043 941 1,605 1,396 1,136 972 969 970 965 1,005 2,696 2,246 w w w w
4
Low-grade scrap and residue 223,403 303,337 500,872 315,294 202,094 140,318 111,243 115,937 95,266 101,223 102,448 136,395 141,250 161,785 161,000 81,400
Refinery brass and other scrap 3,302 2,293 5,885 2,927 3,607 10,217 89,899 125,555 113,950 18,732 41,806 31,102 48,721 46,516 33,710 57,180
Total Alloyed Scrap 861,082 984,957 1,233,847 817,966 784,961 795,793 785,645 767,780 784,138 793,249 808,940 841,087 786,773 839,955 830,410 832,750
Copper recovered from scrap:
Refined from scrap 349,646 420,103 498,459 467,549 401,668 306,537 371,787 406,000 415,000 446,000 480,000 440,757 417,757 433,223 459,788 391,000
Unalloyed powder & castings 15,075 17,017 17,812 14,016 17,186 31,652 15,882 8,446 8,757 10,478 9,282 9,143 8,330 9,316 9,182 11,297
Total unalloyed products 364,721 437,120 516,271 481,565 418,854 338,189 387,669 414,446 423,757 456,478 489,282 449,901 426,087 442,539 469,601 403,000
Brass and bronze 670,712 755,978 976,402 660,152 625,349 735,154 716,833 662,242 736,725 800,221 774,770 800,772 727,618 776,295 753,968 861,000
In aluminum alloys 44,218 48,153 53,608 41,930 36,704 43,511 29,423 45,171 47,932 45,632 41,719 56,489 44,277 55,607 61,049 62,800
From other alloys & chemicals 5,774 5,984 6,244 3,819 2,672 3,060 5,159 4,669 4,672 3,797 2,684 3,412 2,708 1,986 1,077 334

Total copper from scrap: 1,085,425 1,247,235 1,552,525 1,187,466 1,083,579 1,119,914 1,139,084 1,126,528 1,214,059 1,306,891 1,308,455 1,309,529 1,200,690 1,276,426 1,285,695 1,330,000

Source:
1/ U.S.G.S. and U.S.B.M. Minerals Yearbooks and Mineral Industry Surveys.
Gross Weight
W=
2/ Withheld,
Includes data car
Railroad in other
boxesscrap.
13/ Statistical
Gross Weight.
Includes
Information
2
Includes
leaded-yellow brassRailroad car boxes.
3 95low-grade scrap and residues at primary and secondary smelters and refiners.
Includes leaded-yellow brass. 4 Includes
4/
Includes low-grade scrap and residues at primary and secondary smelters and refiners.

87 Statistical Information
 1
Table 17B. U.S. Copper and Copper Alloy Scrap Consumption, 1995-2011
Table 17B.
(metric tons)
U.S. Copper Scrap and Copper Alloy Consumption, 1995–20111
(metric tons)
Scrap Consumption by: 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 p
Plant type:
Brass Mill 886,000 909,000 1,010,000 1,020,000 1,046,800 1,070,000 918,508 929,616 840,921 880,291 874,019 895,437 828,960 739,000 688,000 698,500 707,700
Secondary Smelters & Refiners 695,000 655,000 693,000 644,000 501,000 421,000 370,051 211,283 187,082 182,893 192,465 179,247 181,300 193,800 159,200 156,900 157,400
Foundries and misc. plants 71,500 61,300 62,700 58,700 79,900 96,200 87,478 86,959 85,888 80,742 81,671 75,461 69,500 64,800 67,100 74,800 77,200
Total, gross weight: 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 1,079,760 997,600 914,300 930,200 942,300
Source: 1
Old Scrap 621,000 583,000 594,000 574,000 464,000 414,000 257,875 200,290 224,742 202,441 201,286 159,000 165,000 161,000 134,000 149,000 152,000
New Scrap 1,030,000 1,040,000 1,170,000 1,150,000 1,164,000 1,170,000 1,119,121 1,027,566 889,149 941,485 946,869 991,000 915,000 836,000 780,000 781,000 790,000
Ratio old/new 0.60 0.56 0.51 0.50 0.40 0.35 0.23 0.19 0.25 0.22 0.21 0.16 0.18 0.19 0.17 0.19 0.19
Type of Scrap:
Unalloyed copper:
No. 1 scrap 572,000 533,500 597,800 583,900 538,000 566,900 512,117 484,839 478,724 480,020 478,890 486,114 466,700 433,800 393,800 364,100 369,300
No. 2 scrap, mixed 262,090 254,480 271,670 240,500 154,000 132,120 111,416 51,694 38,032 38,602 45,370 45,890 45,730 57,730 55,640 77,400 80,660
Total Unalloyed: 834,090 787,980 869,470 824,400 692,000 699,020 623,533 536,533 516,756 518,622 524,260 532,004 512,430 491,530 449,440 441,500 449,960
Red Brass 2 81,910 81,090 79,650 71,700 62,800 73,430 67,359 53,185 47,782 50,331 45,159 40,107 43,320 43,780 35,780 37,690 34,690
Cartridge brass 49,900 46,100 66,800 82,600 78,400 72,600 36,430 70,881 80,538 86,659 94,639 94,084 90,700 74,100 87,800 98,200 91,800
Yellow and low Brass 3 424,220 459,930 488,630 486,200 497,200 518,980 464,569 441,930 356,916 366,239 366,308 362,542 327,380 285,170 253,970 260,971 274,930
Automobile Radiators 79,910 70,400 79,870 61,610 55,200 49,450 48,223 36,202 30,409 29,276 29,345 31,139 31,680 27,750 22,100 22,400 22,400
Bronze 25,000 25,900 27,400 27,500 23,670 22,700 31,841 32,481 25,630 29,504 28,208 29,533 29,200 28,800 26,600 28,500 28,300
Nickel silver/cupronickel 20,500 23,300 17,800 17,400 22,300 28,100 19,281 15,430 17,371 20,906 18,683 19,114 14,200 13,100 8,460 9,740 9,620
Aluminum bronze w w w w w w w w w w w w w w w w w
Low-grade scrap and residue 4 92,600 83,100 87,100 124,000 111,000 105,000 70,240 30,196 32,157 35,261 34,955 34,839 23,500 23,300 23,300 23,000 22,900
Refinery brass and other scrap 45,840 48,180 45,070 27,000 19,060 18,910 15,367 11,019 6,331 7,127 6,581 6,763 6,300 6,140 6,380 6,630 7,160
Total Alloyed Scrap 818,410 837,320 896,230 898,010 841,000 889,170 753,310 691,324 597,134 625,303 623,878 618,121 566,280 502,140 464,390 487,131 491,800
Copper recovered from scrap:
Refined from scrap 352,000 345,000 396,000 349,000 229,919 208,000 172,474 69,923 53,281 50,761 47,207 44,777 46,000 53,800 46,400 37,700 37,300
Unalloyed powder & castings 11,299 10,806 10,619 8,305 8,062 8,349 7,775 7,439 346 622 861 746 1,354 1,206 669 1,312 1,154
Total unalloyed products 364,000 355,000 407,000 357,000 237,981 216,349 180,249 77,362 53,627 51,383 48,068 45,523 47,400 55,000 47,100 39,000 37,400
Brass and bronze 887,000 892,000 981,000 987,432 1,000,462 1,010,000 893,363 876,216 818,087 839,975 836,646 845,976 799,000 731,000 675,000 689,000 699,000
In aluminum alloys 64,600 70,700 75,000 76,600 78,200 73,900 64,006 63,177 59,258 60,436 54,517 67,964 72,600 60,700 46,100 51,600 59,600
From other alloys & chemicals 5 307 415 365 215 11,925 14,023 11,871 12,144 13,256 13,300 13,272 9,036 5,943 5,048 5,038 5,039 5,042

Total copper from scrap: 1,320,000 1,320,000 1,460,000 1,422,000 1,328,568 1,314,272 1,149,490 1,029,623 944,228 965,094 952,503 968,499 924,943 851,748 773,238 784,639 801,042

W= Withheld, data in other scrap

1/
Gross Weight scrap Source: USGS and USBM Minerals Yearbooks and Mineral Industry Surveys
2/
Includes Railroad car boxes p Preliminary data (2011 Minerals Yearbook, USGS)
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 97

Statistical Information 88
Table 18. Estimated Secondary By-products for 1998, by Plant-type Sector
(metric tons)

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 ingotmaker 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 inhouse.

89 Statistical Information
Statistical Information 98
Table
Table 19.19. Particulate
Particulate Emission Factors
Emission for Furnaces
Factors Used
for Furnaces in Secondary
Used Copper
in Secondary Smelting
Copper and
Smelting
1/
Process
Alloying and Alloying Process1

(Units in (units
kilograms in kilograms of materials processed)
of material)

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

1.
Source unpublished data, US 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, US EPA 450/4-90-003, March 1990.
ESP = Electrostatic Precipitator. NA= Not Available ND = Not Detected.

Statistical Information 99

Statistical Information 90
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

91
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
Early in 1953, the situation had eased to the point alloy ingots and other crude forms.
where price controls and national and international
allocations of copper were abandoned, although Copper production declined in early 1958, owing
military and Atomic Energy Commission needs were largely to voluntary restrictions in output following the
still to receive preferential treatment. An inadequate surpluses of 1957. Effective Nov. 10, 1958, copper
supply condition was prevalent from 1954 to 1956. items, including copper scrap and copper-base scrap
Due to the continuing shortage of copper, quantity were removed from the Dept. of Commerce positive
export controls were maintained on refined copper list of items requiring export licenses and placed on
through the third quarter of 1956 and on copper scrap the general list for export to all destinations, except
through the third quarter of 1957. Hong Kong, Macao and the Sino-Soviet bloc. At the
same time, after a seven-year suspension, the excise

Figure 14. U.S. Industrial Copper Consumption Trends

and Response to Major Historical Events, 1927-2012
1,000 metric tons, refined copper
3,500

US Industrial Recovery 1985-1999

3,000

2,500
Vietnam War-1964-1973

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

1941-1948 Manufacturing
Capacity-
9 mo. mine 1982 1999-2010
1,500 strike-1967-68 Recession
Depression
6 mo. mine 1974
strike- 1959 Oil Crisis
1,000

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
20
20
20
20
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
08
11

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

92
tax on copper imports was reimposed on July 1. The (1) release of 200,000 tons of copper from the
effective rate was 1.7 cents per pound. On June 11, National stockpile,
1958, the President signed a bill to continue
suspension of duties on metal scrap to June 30, 1959. (2) control of exports of copper and copper scrap
In 1959, the United States was affected by the longest for an indefinite period to conserve domestic
copper mine labor strike to date, lasting 6 months. As supply,
a result, mine output fell 16% from the previous year,
and the substantial loss in production created the (3) legislation to suspend the 1.7 cent-per-pound
need for a larger quantity of imports. On Feb 20, import duty on copper, to encourage a greater
1959, the Dept. of Commerce reimposed controls on inflow of metal, and
all copper exports; shippers were required to declare
destinations of all shipments except those to Canada. (4) imposition of higher margin requirements on
copper trading by directors of the COMEX to
In 1960, imports and exports were almost equal, and lessen speculation in the metal.
in 1961, the United States had again become a net
exporter of copper materials. The priorities provided Copper scrap export limits were put at 30,000 tons in
for under the Defense Materials System (DMS), which 1966 to all countries except Canada. The scrap limit
was basically similar to the Controlled Materials Plan applied to the scrap content containing more than
(CMP) administered during both World War II and the 40% copper and was based on a company’s recent
Korean conflict, were in place in 1962, despite a trade volume. Copper exports other than scrap were
relatively easy supply situation. Nevertheless, exports not limited.
of scrap in 1960 expanded six fold. Stocks of copper
scrap at mills dropped 15% during 1960, as a result of Labor strikes in 1967 reduced U.S. mine capacity by
heavy buying from foreign buyers in Japan and 80% and lasted for nine months. Before the end of
Western Europe. West Germany received about one- December in 1967, shortages and the increasing cost
third of the total. of copper had forced some manufacturers to stop
production. There were also supply restraints from
By 1960, the Government National Stockpile of Central Africa, Chile and Peru, owing largely to labor
copper contained more than 1 million tons of copper. disputes. Some 176,000 tons of refined copper was
With the onset of escalation of the Vietnam War, distributed from the National Stockpile during the first
however, much of this copper would be released. Sale nine months of 1967, but it was insufficient to
of 590,000 tons of copper from the strategic stockpile immediately stem the shortages. Even so, during the
was authorized by legislation in 1965 and 1966, first six months of 1967, U.S. export controls permitted
reducing the stockpile to about 228,000 tons by 1968. the exportation of 16,500 tons of copper scrap, 25,000
The remainder was released in 1974. Only 20,000 tons of refined copper and 10,000 tons of copper
tons of refined copper remained in the National contained in copper-base alloy and copper
Stockpile until 1993, when it was all sold. semifabricated products and master alloys. A virtual
embargo had been in place on exports of domestic
The copper industry established new records, as origin copper since Jan. 20, 1966. The strikes, which
demand began to accelerate late in 1963 and began on July 15, 1967, rapidly disrupted normal
continued strong through 1964. Exports of copper relations between the mines and smelters and
scrap during 1964 increased more than threefold, and refineries. The mines began to stockpile concentrate
exports of copper-base scrap almost doubled. Japan to the point that production was threatened. To relieve
received 44% of the copper scrap and 77% of the this situation, export regulations for mine and smelter
copper-base scrap exported. Copper continued in products were amended to permit licensing for export.
tight supply through 1965, despite an increase of 4% The licensing arrangement was later modified to
in free world mine production. The record production permit the exportation of scrap that could not be
was attained in spite of strikes in Chile, losing an processed in the United States for technical or
estimated 100,000 tons of potential production. economic reasons or because of the strike. Scrap
Substantial quantities of copper also were released exports were concentrated in the last five months of
from the Government National Stockpile. Yet supply 1967, making the annual amount near that for 1966. A
was inadequate to meet record demand for metal 50% increase in exports of copper-base alloy scrap
caused by unprecedented prosperity in the free world accounted for most of the 1967 increase in alloy
and by military action in Vietnam. exports.

On Nov. 17, 1965, the Government announced a 4- At the beginning of 1968, more than 90% of the
point program to reduce inflationary pressures on the domestic copper industry was closed by continuation
price of copper that might impair the defense effort in of the labor strike that started in July 1967. A further
Vietnam. The program called for: 13,800 was withdrawn from the National Stockpile,

93
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.

94
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.

95
 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. Calumet
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

96
(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.

97
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