Processes
The environmental impacts of our copper fabrication and finishing processes are minimal. We have worked hard to ensure that Luvata’s latest technologies are more energy-efficient and environmentally friendly than competing processes.
Our copper cathodes, scrap and alloying metals are melted in foundries and are then cast ready for further processing. The off-gases from the furnaces are removed by filtration, and where necessary, by afterburning. Any recovered dusts are recycled to up-stream smelters. The cooling waters that come directly into contact with cast products are treated to remove particles and are then re-circulated.
The modern casting processes that we have developed are environmentally more sustainable than conventional processes. They are continuous, and produce sheets, wire rods or tubes that are already close in shape and dimension to being finished products. This reduces further processing stages, which means that less energy is consumed and that there is less wastage.
The cast shapes are then sent to mills to be turned into semi-finished products. This process is usually just surface finishing and the environmental impact is minimal.
Oxidised surfaces can be removed by pickling with sulphuric acid liquid. The pickling liquids are recycled or treated along with the flushing waters which also contain copper traces. Alternatively the oxide scale can be removed mechanically, either by milling or sand blasting. In this case, the removed copper particles and dust are separated from the gas stream and are recycled.
Emulsions are used as cooling and lubricating agents in several fabrication processes. Used emulsions are either recycled through ultra-filtration or destroyed by evaporation. The small amount of oil residue produced is sent to hazardous waste treatment plants.