How Can Waste Copper Be Transformed into 5N Ultra-Pure Copper for Clean Energy?

Yes, there’s an innovative process developed by the Pure CuRE project that makes this possible. Instead of using traditional recycling, which often lowers the quality of copper, they combine zone refining with vacuum inert gas atomization. This allows waste copper—like old electrical cables—to be refined to 99.999% purity, also known as 5N copper. The process also keeps oxygen levels extremely low, far better than standard recycled copper. That means the reclaimed copper can be used in advanced applications like semiconductors, nuclear systems, and energy storage, where high purity is essential.

Old or discarded copper can be transformed into high-purity 5N copper (99.999% pure) through an innovative process combining zone refining and vacuum inert gas atomization. This method, developed by Project Pure CuRE, addresses the limitations of conventional recycling, which often degrades copper quality due to oxidation and impurity retention. Zone refining selectively purifies copper by passing a molten zone through the material, segregating impurities to the ends, while vacuum inert gas atomization converts the purified copper into fine powder with oxygen content as low as 50–100 ppm, far below the 500 ppm industry standard. This ensures the copper retains its electrical and thermal properties, making it suitable for critical applications like semiconductors, nuclear systems, and energy storage.

Such advanced recycling reduces reliance on imported raw materials by creating a domestic, circular supply chain. For instance, the UK-based project processes cable-grade waste copper into ultra-pure powder, directly supporting clean energy technologies like electric vehicles and renewables. This enhances supply chain resilience, aligns with net-zero goals by minimizing mining-related emissions, and establishes a sustainable model for critical mineral recovery. By turning waste into high-value material, it mitigates supply risks and fosters economic and environmental sustainability.

Old or discarded copper can be turned into 5N - purity copper through advanced recycling processes. One such process is the one developed by Project Pure CuRE, which combines zone melting and vacuum inert gas atomization technologies.

First, the waste copper, usually from cable - grade sources, is processed through zone melting. This technique utilizes the principle that impurities have different solubilities in the solid and liquid phases of copper. By moving a heated zone along the copper rod, impurities are segregated to one end, thus purifying the copper. Then, the purified copper is subjected to vacuum inert gas atomization. In this process, the copper is melted in a vacuum and then atomized by an inert gas jet, resulting in the formation of ultra - pure copper powder. The oxygen content of the copper powder produced by this process can be as low as 50 to 100 ppm, much lower than the industry standard of 500 ppm.

This advanced recycling process is of great significance in the professional field. In the field of semiconductors and energy storage, high - purity copper is essential because even trace amounts of impurities can affect the electrical and thermal properties of copper. Traditional recycling methods often lead to quality degradation, unable to meet the requirements of these critical applications. The new process can retain the properties of copper, enabling it to be reused in high - tech applications.

In terms of reducing reliance on imported raw materials, domestic production of high - purity copper through recycling can reduce a country's dependence on overseas copper supplies, enhancing the security of the domestic supply chain. For the sustainable supply chain of the future, recycling waste copper not only saves natural resources but also reduces energy consumption and emissions compared to mining and refining primary copper. It is in line with the concept of circular economy and contributes to the sustainable development of the copper industry.