Figure 1.1: Variations in the rate of copper extraction, past 5000 years

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1 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 1 Figure 1.1: Variations in the rate of copper extraction, past 5 years Copper production (metric tons/year) Source: Landner & Lindström 1999, Figure Beginning of Bronze Age Use of coinage Rise & fall of Athens Decline of Roman metallurgy & mining Roman Republic & Empire Industrial Revolution Sung dynasty of China Peak production in Swedish Falun mine 5 3 years ago 2 1

2 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 2 Figure 1.2: Copper production at the mine in Falun, Sweden 3 25 metric tons trend actual average

3 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 3 8 Figure 1.3: Total production of copper from ores in the "Western World", Copper from ore (1 metric tons) Source: Landner & Lindström 1999, Figure 4.1

4 1 metric tons R.U. Ayres et al The life cycle of copper, its co-products and byproducts 4 Figure 1.4: Total consumption of copper in the "Western World", Consumption, refined & recycled Recycled copper Year Source: Landner & Lindström 1999, Figure 4.2

5 R.U. Ayres et al The life cycle of copper, its co-products and byproducts Figure 1.5: Historical production of lead 9 (4 x 1 kg in 1975) discovery of cupellation bronze age stimulation Source: adapted from Patterson et al. 197 coinage B.C. Roman Empire fall of Roman Empire mining renaissance in Europe A.D gasoline additives Industrial Revolution Lead produced (kilograms per year)

6 R.U. Ayres et al The life cycle of copper, its co-products and byproducts discovery of cupellation 5 Source: [Boutron 1998, p. 158] use of coinage Rise and fall of Athens exhaustion of Roman lead mines Roman Republic & Empire silver production in Germany industrial revolution Spanish production of silver in New World years before present Age of Greenland ice(years before present) Pb concentration in Greenland ice(pg/g) Global Pb production (metric tons/year Figure 1.6: Greenland ice and lead production

7 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 7 Figure 1.7: Probable distribution of a geochemically scarce metal in the Earth's crust Amount Current mining Source: [Skinner 1976, Figure 4] Grade (%)

8 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 8 Figure 2.1: Mass flows (kg) in the production of 1 MTcopper (simplified processes, typical material mixes) utilities -235 mj 616 Flotation reagents 133 Sulfide Cu-ore % SULFIDE CU-ORE CONCEN- TRATION 85% eff wastes Tailings Silicon dioxide 254 Off 5643 Limestone Water 188 SULFURIC ACID 534 ROASTING AND SMELTING (SULFIDE Cu-ORE) wastes wastes Sulfide /oxide Cu-ore H 2 SO Flotation reagents 97 3 Tailings.58% Cu-ORE SOL- VENT EX- TRACT- TION ELEC- TRO- WIN- ING (SXEW) LEACH- ING CON- CEN- TRA- TION Limestone 2984 Sulfide Cu-ore concentrate wastes Leach solids nomally to further recovery ELEC- TRO- LYTIC REFIN- ING Anode wastes copper -31 Refined copper Slime solids 28 normally to further recovery 3 normally to further recovery Slags

9 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 9 Figure 2.2: US copper ore grade percent, : beginning of open pit mining 192+: flotation process for concentrating sulfide ores Percent Herfindahl (avg) Coppa McMahon MYB-all MYB-conc

10 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 1 Flotation reagents % SULFIDE CU-ORE CONCEN- TRATION 85% eff Limestone 16 Sulfide Cu-ore utilities waste heat Tailings 5974 Figure 2.3: Exergy flows (mj) in the production of 1 MTcopper (simplified processes, typical material mixes) 248 Silicon dioxide 1 Off 995 Limestone Water 97 utilities utilities -235 SULFURIC ACID 432 ROASTING AND SMELTING (SULFIDE Cu-ORE) waste heat waste heat H 2 SO Tailings 1258 utilities % Cu-ORE waste heat Leach solids 5868 nomally to further recovery 91 <1 utilities 792 ELEC- TRO- LYTIC REFIN- ING sulfide ore concentrate SOL- VENT 45 LEACH- EX ING Sulfide TRACT- Anode Refined /oxide TION copper waste heat copper -798 Cu-ore ELEC CON- TRO- CEN- WIN- Slime Flotation TRA- solids reagents ING 4574 TION 44 <1 (SXEW) normally to further recovery to further recovery Slags

11 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 11 Figure 2.4: Primary copper mass and exergy flows Material composition & processes are exemplary only s are pretreatment & pre-reprocessing Process water included for chemical reactions only Cooling water not included; overburden not included s include depleted air and water vapor utility exergy 45.3 gj UTILITIES INPUTS mass 24 MT MATERIAL INPUTS 1 MT PRIMARY COPPER PRODUCTION 73% from sulfide ores,.63% Cu 27% from oxide ores,.58% Cu PRODUCTS & BYPRODUCTS mass (inc. byproducts) 1.67MT embodied exergy 3.22 gj embodied exergy 67.8 gj WASTES & LOSSES ore 19 MT (61.1 gj) air 6.2MT (.318 gj) limestone 4.93 MT (.264 gj) process water 1.88 MT (.971 gj) other.484 MT (5.95 gj) waste mass 22 MT waste embodied exergy 21.4 gj waste heat exergy 9.3 gj product copper MT gj potential byproduct sulfuric acid.667 MT 1.11 gj

12 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 12 6 Figure 2.5: France; copper foundry production, imports, exports &apparent consumption, (3 year moving averages) Copper (1 metric tons) Foundry production Imports Exports Apparent consumption

13 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 13 6 Figure 2.6: United Kingdom; copper foundry production, imports, exports &apparent consumption, (3 year moving averages) Copper (1 metric tons) 4 2 Foundry production Imports Exports Apparent consumption

14 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 14 Figure 2.7: Germany; copper foundry production, imports, exports &apparent consumption, (3 year moving averages) 1 8 Foundry production Imports Exports Apparent consumption Copper (1 metric tons)

15 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 15 Figure 2.8: Sweden; copper foundry production, imports, exports &apparent consumption, (3 year moving averages) Copper (1 metric tons) 1 Foundry production Imports Exports Apparent consumption

16 R.U. Ayres et al The life cycle of copper, its co-products and byproducts Figure 2.9: Japan; copper foundry production, imports, exports &apparent consumption, (3 year moving averages) 14 Copper (1 metric tons) Foundry production Imports Exports Apparent consumption

17 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 17 Copper (1 metric tons) Figure 2.1: USA; copper foundry production, imports, exports &apparent consumption, (3 year moving averages) Foundry production Imports Exports Apparent consumption

18 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 18 Figure 2.11: Electrical consumption of copper; US percent of total consumption

19 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 19 Figure 2.12: Telecommunications capacity Capacity of major telecommunications highways (bits per second) voice channel is taken as equivalent to 2 bps in plotting these points. Numbers in parentheses give voice channels carried. coaxial cable and microwave highways (32) coaxial cable links (6) Communication satellites carrier telephony first used (12 per wire pair) telephone lines first constructed Lasers microwave links (18) Baudot multiplex telegraph (16 telegraph machines per line) printing telegraph systems early telegraphy, Morse code dots and dashes oscillating needle telegraph experiments planned helical waveguides (1, or equivalent) Year

20 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 2 Mining 74+? ore 74+?? 2 imports 13 imports 15 imports 63 imports 42 Concentration 8 77 concentrate 9 66 Smelting 98 blister copper 97 Refining 97 cathode copper Semi-manufacturing 196 final products 92 waste? slag waste 1 24 other 1 old scrap 28? scrap 59 old scrap 11 Reprocessing 1 exports 24 exports? 3 exports 4 exports 13 waste 1? Figure 2.13: Atentative copper balance for Sweden,199

21 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 21 Figure 2.14: Price of copper on the New York market, (cents per pound in current and constant 1987 US dollars) Undeflated copper price (cents/pound) Cents per pound (deflated by BLS PPI, 1967=1)

22 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 22 Figure 2.15: Estimated accumulation of copper-in-use in USA, million metric tons in use at year end year Sources: McMahon 1964, Historical Statistics, and Minerals Yearbooks

23 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 23 Figure 2.16: Annual change in the copper store in the Swedish technosphere: Copper (1 metric tons per year) Source: Landner & Lindström 1999, Figure 5.6

24 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 24 Figure 2.17: Cumulative evolution of the copper reservoir in the Swedish technosphere (195 base) 75 6 Copper (1 metric tons) Source: Landner & Lindström 1999, Figure 4.6

25 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 25 Figure 2.18: World copper production and the US manufacturing production index, with projections to fitted fitted fitted US manufacturing production index (see scale on left) World copper production - million metric tons US manufacturing production index = fitted Global copper production (see scale on right)

26 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 26 Figure 2.19: Historical and modeled Intensity of Use (consumption of refined copper) as a function of GDP/capita in (kg/capita, year) REF (kg/kusd'9) ASIA OECD9.2. ALM Model IU (kusd'9/capita, year)

27 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 27 Figure 2:2: Model of the global copper system S1) Primary resources Global modeling Four world region modeling S6) New scrap x (t) = x (t-1) x (t) 12 P2) Concentration x x = l (t) x = (1-l (t)) x 2 11 c c 12 x (t) 23 P3) Smelting & refining x 3 12 = l s(x + x + x ) x 34p = (1-l s)x23 x = (1-l )(x + x ) 34s s x (t) 34p x (t) 34s x (t) x (t) P4) Production of semi- P5) Production of goods manufactures x (t) x = x + x + x 45 x = l x 45 34p 34s p 45 x 57 = (1-l p)gx45 x = (1-l )( 1-g)x 58 p 45 x (t) 57 x (t) 58 S7) Long-lived goods x =sum(x (t ) u(t,t )) t < t S8) Short-lived goods x =sum(x (t ) u(t,t )) t < t x (t) 1 3 x (t) 93 P9) Utilization of long-lived goods x 93 = hlx79 x = (1- h )x 9 13 l 79 P1) Utilization of short-lived goods x 1 3 = hsx8 1 x = (1- h )x 1 14 s 8 1 x (t) 8 1 x (t) 79 x (t) 2 11 x (t) x (t) x (t) S11 ) Gangue S12 ) Slag S13 ) from long-lived goods S14 ) from short-lived goods

28 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 28 Figure 2.21: Global copper recycling (separation) efficiency 8 scenarios 8% Sc8 Sc6 Sc7 Sc5 7% 6% Sc4 Sc2 Sc3 Sc1 5% 4%

29 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 29 Figure 2.22: Global copper recycling rate 8 scenarios 6% 5% 4% Sc8 Sc7 Sc6 Sc5 Sc4 Sc2 Sc3 Sc1 3% 2% 1% %

30 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 3 Figure 2.23: Global consumption of refined copper, scenarios 1 through 4 (low recycling efficiency) 1 9 ConSc1 8 7 ConSc2 ConSc4 million mteric tons ConSc

31 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 31 Figure 2.24: Regional consumption of refined copper; scenarios 1 and ASIA 4 35 ALM 3 million mteric tons OECD9 REF

32 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 32 Figure 2.25: Regional consumption of refined copper; scenarios 3 and million mteric tons ASIA ALM 1 OECD9 5 REF

33 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 33 1 Figure 2.26: Regional consumption of refined copper; scenarios 2 and ASIA million mteric tons ALM 2 1 OECD9 REF

34 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 34 1 Figure 2.27: Regional consumption of refined copper; scenarios 4 and million mteric tons ASIA ALM 2 OECD9 1 REF

35 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 35 9 Figure 2.28: Global mine production of copper, , MMT 8 scenarios Herfindahl Sc1 Sc5 million metric tons Sc3 Sc7 Sc2 Sc6 Sc4 Sc

36 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 36 Figure 2.29: Cumulative global mine production of copper, , MMT 5, 4, plus 1x reserve base plus 9x reserve base plus 8x reserve base plus 7x reserve base Sc1 Sc5 Sc2 Sc6 Sc3 Sc7 Sc4 Sc8 plus 6x reserve base million metric tons 3, 2, plus 5x reserve base plus 4x reserve base plus 3x reserve base Herfindahl 1, plus 1x reserve base plus 2x reserve base copper mined to date

37 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 37 Figure 2.3: Global stock of waste copper, , MMT 8 scenarios 2, Sc1 Sc2 Sc3 Sc4 1,5 million metric tons 1, Sc5 Sc6 Sc7 Sc

38 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 38 Figure 2.31: Global stock of long-lived copper products, , MMT 8 scenarios 3,5 Sc5 Sc6 3, 2,5 Sc7 Sc1 Sc8 Sc2 Sc3 Sc4 million metric tons 2, 1,5 1,

39 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 39 3 Figure 2.32: Global stock of short-lived copper products, , MMT 8 scenarios Sc Sc6 Sc7 Sc1 Sc8 million metric tons 15 1 Sc2 Sc3 Sc

40 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 4 Figure 3.1: Mass flows (kg) in the production of 1 MTlead (simplified processes, typical material mixes) net usable heat 175 mj Off 5459 Water 192 SULFURIC ACID PRODUCTION wastes H 2 SO gas Flotation reagents 12 Limestone 64 Ore % ORE BENE- FICIA- TION 95% eff Fluxes 2691 Con centrate 3312 SINTER- ING Lead sinter 1435 Coking coal 665 Limestone 92 BLAST FUR- NACE Sulfur 3 Coal 2 Lead bullion 16 DROSS- ING Bullion, drossed 133 REFIN- ING Lead, refined % % % % % % wastes wastes wastes wastes wastes Gangue Slag, dust Slag, dust Slag, dust Slag normally to further recovery normally to further recovery normally to further recovery normally to further recovery

41 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 41 Figure 3.3: Primary lead unit mass and exergy flows M at erial com posit ion & processes are ex em plary only s are pretreatm ent & pre-reprocessing Process Cooling water included not included; for chemical overburden reactions not only included s include depleted air and water vapor utility exergy 28.8 gj UTILITIES INPUTS mass 68.5 MT embodied exergy 36.9 gj MATERIAL INPUTS 1 MT PRIMARY LEAD PRODUCTION (5% Pb ore) PRODUCTS & BYPRODUCTS mass (inc. byproduct) 2.48 MT embodied exergy 3.59 gj ore 52.2MT (11.8 gj) air 12.3 MT (.635 gj) coking coal.82 MT (24.8 gj) limestone 3.6 MT (.164 gj) process water.141 MT (.7 gj) other.11 MT (.61 gj) waste mass 66. MT WASTES & LOSSES waste embodied exergy 9.91 gj waste heat exergy 39.7 gj product lead 1 MT 1.12 gj potential byproduct sulfuric acid MT 2.46 gj

42 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 42 Figure 3.4: Mass flows (kg) in the production of 1 MTzinc (simplified processes, typical material mixes) net usable heat 157 mj Flotation reagents 16 Off 376 Limestone 12 Sulfide ore Tailings normally to further recovery wastes SULFIDE CONCEN- TRATE, ROAST & SMELT Slags wastes Dust particles Water 692 (9%) SULFIDE Zn-ORE CONCEN- TRATION 85% eff` Sulfide concentrate 2526 Coking coal wastes utilities H 2 SO SULFIDE/OXIDE Zn-ORE (8.3%) SINTERING & RETORTING Zinc (95%) 1184 Slime solids 386 normally to further recovery SUL- FURIC ACID FINAL REFIN- ING wastes Slab zinc 1 Limestone & sand 3 Sulfide /oxide ore 3383 solids wastes Dust particles normally to further recovery

43 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 43 Figure 3.4: Mass flows (kg) in the production of 1 MTzinc (simplified processes, typical material mixes) net usable heat 157 mj Flotation reagents 16 Off 376 Limestone 12 Sulfide ore Tailings normally to further recovery wastes SULFIDE CONCEN- TRATE, ROAST & SMELT Slags wastes Dust particles Water 692 (9%) SULFIDE Zn-ORE CONCEN- TRATION 85% eff` Sulfide concentrate 2526 Coking coal wastes utilities H 2 SO SULFIDE/OXIDE Zn-ORE (8.3%) SINTERING & RETORTING Zinc (95%) 1184 Slime solids 386 normally to further recovery SUL- FURIC ACID FINAL REFIN- ING wastes Slab zinc 1 Limestone & sand 3 Sulfide /oxide ore 3383 solids wastes Dust particles normally to further recovery

44 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 44 Figure 3.5: Exergy flows (mj) in the production of 1 MTzinc (simplified processes, typical material mixes) net usable heat 157 Flotation reagents 5 Off 5983 Limestone 5 Sulfide ore 1571 utilities SULFIDE Zn-ORE (9%) CONCEN- TRATION waste heat Tailings Sulfide concentrate SULFIDE CONCEN- TRATE, ROAST & SMELT Slags 396 utilities waste heat Dust particles 4 65 Water 35 Coking coal waste heat utilities 748 H 2 SO Zinc (95%) 59 Slime solids 281 utilities 1461 SUL- FURIC ACID FINAL REFIN- ING waste heat Slab zinc 5182 normally to further recovery 66 Zn-ORE (8.3%) SINTERING & RETORTING normally to further recovery Limestone & sand 1 Sulfide /oxide ore 3383 solids waste heat Dust particles normally to further recovery

45 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 45 Figure 3.6: Overall unit zinc mass and exergy flows Material composition & processes are exemplary only s are pretreatment & pre-reprocessing Process water included for chemical reactions only Cooling water not included; overburden not included s include depleted air and water vapor utility exergy 63.3 gj UTILITIES INPUTS mass 37.9 MT embodied exergy 62.2 gj MATERIAL INPUTS 1 MT PRIMARY ZINC PRODUCTION 75% from sulfide ores, 9% Zn 25% from oxide ores, 8.3% Zn PRODUCTS & BYPRODUCTS mass ( inc. byproducts) 2.62 MT embodied exergy gj ore 19.1 MT (18.5 gj) air 16.7 MT (.861 gj) coking coal 1.18 MT (42.8 gj) process water.692 MT (.35 gj) limestone & other.147 MT (.12 gj) waste mass 35.3 MT WASTES & LOSSES waste embodied exergy 18.5 gj waste heat exergy 99.2 gj product slab zinc 1 MT gj potential byproduct sulfuric acid MT gj

46 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 46 Figure 3.7: Arsenic demand patterns in the United States, (kmt) metric tons (As content) Wood preservatives Agricultural chemicals Other Total Source: USBM, USGS. Minerals Yearbooks, various years, "Arsenic" Table 1

47 R.U. Ayres et al The life cycle of copper, its co-products and byproducts 47 Figure Annex 1 (1.2): Copper production at the mine in Falun, Sweden 3 25 metric tons trend actual average

Materials Production. T. G. Gutowski. with significant contributions by A. Thiriez 2.83/

Materials Production. T. G. Gutowski. with significant contributions by A. Thiriez 2.83/ Materials Production T. G. Gutowski with significant contributions by A. Thiriez 2.83/2.813 2008 Reading a) Masini and Ayres, An Application of Exergy Accounting to Five Basic Metal Industries, 2001 (click