Copper Scrap Recovery Plant – From Scrap Copper to Cathode Copper
Copper scrap is an important secondary source of copper. With proper sorting, preparation, smelting, fire refining and electrolytic refining, copper scrap can be converted into high-purity cathode copper and returned to the production cycle.
PRS provides integrated solutions for copper scrap recovery plants, covering both the pyrometallurgical section and the electrolytic refining section.
This project is designed to process copper scrap with a copper content of Cu ≥ 93% and produce anode copper at approximately 99.3% Cu, followed by electrolytic refining to produce cathode copper ≥ 99.95% Cu.
The complete process combines scrap preparation, melting, fire refining, anode casting and copper electrorefining into one production system.
From Scrap Copper to Cathode Copper
The video below shows the actual production process, giving a direct view of how recycled copper moves through the production line and is eventually converted into cathode copper.
This process demonstrates the connection between copper scrap recycling, fire refining and electrolytic copper refining.
Project Data
| Item | Project Parameter |
|---|---|
| Process | Copper Scrap Recycling + Fire Refining + Electrolytic Refining |
| Raw Material | Copper Scrap |
| Feed Copper Grade | Cu ≥ 93% |
| Scrap Treatment Capacity | 1,000–100,000 tpa |
| Fire Refining | Oxidation + Reduction |
| Direct Cu Recovery in Fire Refining | 98.4% |
| Anode Copper | Cu ≈ 99.3% |
| Final Product | Cathode Copper |
| Cathode Copper Grade | Cu ≥ 99.95% |
Copper Scrap Recovery Process
The project combines pyrometallurgical refining and electrolytic refining.
Process Flow
Copper Scrap (Cu ≥ 93%)
↓
Scrap Pre-treatment
Sorting + Shearing + Baling
↓
Melting / Smelting Furnace
↓
Crude Copper Melt
↓
Fire Refining
Oxidation + Reduction
↓
Anode Casting Wheel
↓
Anode Copper Plates (Cu ≈ 99.3%)
↓
Electrolytic Refining Workshop
↓
Cathode Copper (Cu ≥ 99.95%)
During the pyrometallurgical stages, generated off-gas is collected and treated through dust collection and acid gas treatment systems.
Pyrometallurgical Section
The first part of the plant focuses on recovering copper from scrap and upgrading the molten copper through fire refining.
Scrap is first sorted and prepared for furnace charging. After melting, the crude copper is transferred to the refining furnace, where oxidation and reduction are carried out to adjust the copper quality before casting.
Main Equipment
- Copper Scrap Classification Equipment
- Hydraulic Scrap Shear
- Scrap Baler
- Melting / Smelting Furnace
- Anode Refining Furnace
- Anode Casting Wheel
- Off-Gas Treatment System
- Overhead Crane
Electrolytic Refining Workshop
The refined anode copper enters the electrolytic refining section for further purification.
Anode plates and permanent stainless steel cathode plates are installed in the electrolytic cells. During electrolysis, copper is transferred from the anode and deposited onto the cathode plate, producing high-purity cathode copper.
Electrolytic Refining Flow
Anode Copper Plates
↓
Anode Preparation
↓
Electrolytic Cells
↓
Copper Deposition
↓
Cathode Stripping
↓
Cathode Copper ≥ 99.95%
Core Equipment for the Electrolytic Tankhouse
The electrolytic refining workshop consists of several interconnected systems. Equipment selection and layout are coordinated according to production capacity, cell arrangement and material handling requirements.
The main production units where copper is deposited onto the cathode plates.
Used as the cathode substrate for copper deposition.
Provide the anode surface required for the electrolytic refining process.
Provides the electrical connection between the rectifier system and electrolytic cells.
Distribute circulating electrolyte evenly through the cells.
-
Tankhouse Crane
Handles anode and cathode plates during cell loading, maintenance and production operations.
Prepares anode plates for stable operation in the electrolytic cells.
Removes deposited copper from permanent stainless steel cathode plates.
Plant Layout & 3D Design
A practical copper recycling plant requires coordinated planning of the process route, equipment arrangement and material handling.
The layout follows the main production sequence:
Scrap Preparation → Melting → Fire Refining → Anode Casting → Anode Preparation → Electrolytic Refining → Cathode Handling
The electrolytic refining workshop can be arranged according to the required production capacity, cell configuration, crane operation and material flow.
3D modeling can also be used during project design to review equipment positions, piping routes, operating space and material handling paths before installation.
A Complete Copper Recycling Route
Copper recycling does not end with scrap melting.
The complete route connects scrap preparation, fire refining, anode casting and electrolytic refining, allowing recovered copper to be transformed into high-purity cathode copper.
Copper Scrap
→ Fire-Refined Copper
→ Anode Copper
→ Electrolytic Refining
→ Cathode Copper
PRS can provide the key equipment and engineering solutions required across both the pyrometallurgical and electrolytic refining sections, with the final process and equipment configuration developed according to the customer's raw material, production capacity and product requirements.
Ready to Start Your Copper Recycling Project?
Have copper scrap and a target production capacity?
Contact PRS to discuss your copper scrap recovery and cathode copper production project.