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Montreal Copper Recycling Initiative Highlighted by Nexans' Efforts
In an industrial suburb of Montreal, a remarkable transformation process is taking place at a foundry operated by Nexans, a leading wire and cable manufacturer. Here, sheets of copper journey along a conveyor belt, ultimately plunging into a blazing furnace. Alongside these sheets are pieces of discarded copper wire, which also find their way into the same furnace. The result is liquid copper, visually marked by a distinctive green flame. This molten metal transfers to a secondary furnace before flowing out as a river of vivid orange copper, destined to be molded into copper rods—the essential raw material for producing copper wire.
For almost a century, this Nexans mill has specialized in creating copper rods from ore. However, a significant shift is underway as the facility now incorporates an increasing quantity of recycled copper into its production. Currently, these rods feature approximately 14% recycled metal, with aspirations to elevate this figure to 20%. Nexans CEO Christopher Guérin emphasizes the company’s commitment to sustainability, stating, "We say to our customers: Your waste of today, your scrap of today is your energy of tomorrow, so bring back your scrap."
The broader industry has long practiced the reuse and recycling of copper to a certain degree. However, these efforts are gaining momentum due to a pronounced shift away from fossil fuels aimed at reducing greenhouse gas emissions. The growing initiative to electrify buildings, vehicles, and manufacturing processes demands more copper. In addition, the construction sector, along with the proliferation of cell phones and data centers, contributes significantly to the surging demand for this versatile metal.
Recycling copper is crucial because each ton repurposed translates to around 200 tons of rock that do not need to be mined—although this figure varies depending on the ore's richness. This is vital as mining activities can lead to environmental degradation, including soil erosion, water contamination, biodiversity threats, and air pollution. Notably, copper stands out as an ideal candidate for recycling, maintaining its value and performance through infinite cycles of reuse, as highlighted by Guérin.
Every day, up to 10 trucks deliver bare wire, cable, and other copper scrap to the Nexans mill. The sources of this scrap range from customers to scrap dealers, and high purity is essential for its role in electrical conductivity. Nexans leverages enormous volumes of copper, surpassing the weight of the Statue of Liberty by more than 2,600 times annually. Daniel Yergin, an energy expert and vice chairman of S&P Global, underscores copper's pivotal role, noting, “We depend on electricity for everything now. None of it works without copper.”
While aluminum competes in the realm of electrical wiring, it is notably energy-intensive to produce. Rising electricity prices have led some aluminum smelters to reduce output or shut down, further boosting copper's demand. According to the International Copper Association, about two-thirds of all copper produced in the past century remains in use, largely deployed in electrical grids, home appliances, and communication systems. As these applications reach the end of their lifecycle, they present a substantial reservoir of material for future recycling efforts.
Colin Williams, program coordinator for the USGS Mineral Resources Program, advocates for heightened recycling efforts to tap into what he terms the “urban mine.” He explains, "It increases the supply available. ... It reduces the energy and environmental impacts associated with new mining by being able to reuse material we’ve already mined. It’s an important step."
