Simulation-based exergy, thermo-economic and environmental footprint analysis of primary copper production

The transition from a Linear to Circular Economy has become a societal challenge to be tackled. However, the increasing complexity of materials and products increases also the sophistication of the circular economy systems required to deal with them. These systems are very resource consuming, therefore, a rigorous evaluation of the impact of every “actor” in circular economy must be done at design and operation stages to ensure the sustainability of the metal-production value chain.

A circular economy system implies, among others, low consumption of energy and material resources and low production of wastes or pollutant emissions. Its sustainability cannot therefore be evaluated just with one indicator. In this paper, we integrate indicators such as recovery rates, environmental impact indicators, as well as the quantities and qualities of the flows, losses and emissions, quantified through exergy. These must all be considered and evaluated simultaneously to perform a rigorous sustainability analysis.

The challenges of achieving a circular processing system and society are illustrated using a unique copper flowsheet that covers the complete processing chain from ore to refined metal including among others minor elements refining, scrap recycling, residue processing, steam utilization, sulphur capture and power generation in 129 unit operations linked by 289 streams and all the compositional and thermochemical detail. Using a simulation-based approach, two scenarios have been studied and compared: (i) a representative primary copper flowsheet and (ii) excluding all waste treatment processes. This unique simulated flowsheet permits a complete evaluation of various scenarios of all copper related processing options (while any additional unit operations can also be added) and also rigorously permits an allocation of impacts of all flows, products, residues etc. as a function of the complete mineral composition.

This approach to evaluating systems shows how to estimate the true losses from a system and will be a key approach to evaluate the true circularity of the circular economy system.