What Equipment Is Used in Secondary Copper Smelting?

With the rising demand for sustainable production and circular economy practices, secondary copper smelting—the process of recovering copper from scrap and industrial waste—has become increasingly vital. Unlike primary smelting, which uses mined ore, secondary smelting relies on copper-containing waste such as wires, cables, circuit boards, and residues from other industries.

But what kind of equipment is required to build an efficient, clean, and high-yield secondary copper smelting facility? In this article, we’ll explore the essential systems used in modern secondary copper smelting lines, especially those developed by industry leaders like RE TECH.

What Is Secondary Copper Smelting?

Secondary copper smelting refers to the recovery of copper from scrap materials—such as scrap cables, copper slag, alloy residues, circuit boards, and contaminated metal dust—using thermal and chemical treatment methods.

The process requires specialized equipment that can handle complex feedstock, remove impurities like lead, tin, zinc, and iron, and ultimately refine the recovered copper into usable forms such as cathodes or ingots.

Key Equipment Used in Secondary Copper Smelting

1. Pre-Treatment & Sorting System

• Purpose: To clean, size, and classify copper scrap before smelting.

• Equipment includes:

• Crushing and shredding machines

• Magnetic separators (to remove iron)

• Eddy current separators and air classifiers

• Dust collection and filtration systems

RE TECH integrates automatic sorting lines for handling copper scrap with plastic, rubber, and non-ferrous contamination.

2. Oxygen-Enriched Side-Blown Smelting Furnace

• Purpose: The heart of the smelting process, where copper is melted, impurities are separated, and crude copper is produced.

• Why it matters:

• Tolerates mixed and low-grade feedstock

• Efficient separation of non-copper metals (Zn, Pb, Sn)

• Energy-saving and low emission

• Technology from RE TECH:
  Their patented oxygen-enriched side-blown bath smelting furnace allows for flexible operation, high thermal efficiency, and superior impurity control.

3. Converting & Slag Cleaning Furnace

• Purpose: To further oxidize and remove impurities from crude copper and recover valuable metals from slag.

• Common equipment:

• Anode refining furnace

• Slag settling furnace

• Holding furnace (for ingot casting)

RE TECH offers integrated slag treatment units to maximize metal recovery and reduce waste.

4. Dust Collection & Waste Gas Treatment

• Purpose: To capture fine metal particles and remove harmful gases like SO₂ from the flue gas.

• Key equipment:

• Baghouse filters

• Desulfurization towers

• Gas cooling and scrubbing units

• Optional acid recovery system (sulfuric acid production)

RE TECH provides waste gas treatment systems that comply with China’s national standards and international emission norms.

5. Copper Refining & Casting System

• Purpose: To refine the blister copper and cast it into usable forms such as:

• Copper anodes for electrolysis

• Copper rods or ingots

• Typical equipment:

• Fire refining furnace

• Casting wheel or mold

• Cooling conveyors

6. Automation & Control

• Purpose: To monitor and optimize plant operations in real time.

• Includes:

• PLC or SCADA systems

• Integrated dashboards for temperature, pressure, metal yield, and emissions

• Remote diagnostics and maintenance features

Optional Add-ons Based on Project Needs

• Acid Recovery System (for sulfur-bearing feedstock)

• Metal Slag Granulation Unit

• Rotary Kiln Pre-Treatment (for e-waste and volatile elements)

• Wet Electrostatic Precipitator (for ultra-fine dust control)

RE TECH's Experience in Secondary Copper Smelting

RE TECH has provided complete solutions for copper, lead, and zinc secondary smelting, particularly in multi-metal integrated resource recovery projects. Their systems are designed for:

• Complex, multi-element feedstock

• High metal recovery rates

• Low energy consumption

• Full compliance with environmental regulations

• Turnkey delivery with EPC support

Their large-scale copper recovery projects often integrate slag recycling, sulfur gas recovery, and automated refining, making them ideal for industrial clients in Asia, Africa, and Latin America.

Conclusion

Secondary copper smelting is a technology-intensive process that requires careful integration of pre-treatment, smelting, refining, and environmental protection systems. By choosing reliable and scalable equipment—like RE TECH’s side-blown furnace and refining lines—operators can maximize copper recovery while ensuring sustainability and compliance.

Whether you're launching a new project or upgrading an existing one, having the right equipment is the key to long-term efficiency and profitability.