Pseudo-Closed-Loop Metallurgy and Quality-Adjusted Circularity of Secondary Copper: A Conceptual Framework

Mass-based circularity indicators, such as ISO 59020:2024, quantify material recovery as a share of total throughput but do not account for chemical composition or functional performance, as a consequence of their sector-agnostic design. In copper metallurgical systems, trace tramp elements (e.g., As, Sb, Bi, Fe, Sn, Ni) present in WEEE-derived scrap, anode slimes, and refinery residues can significantly reduce electrical conductivity. Even at nominal purities of ≥99.7 wt.% Cu, conductivity may drop to 85.0–88.0% IACS, as illustrated by selected reported cases—a level of functional degradation that remains undetected by mass-based accounting. Analysis of Grade A cathode standards (EN 1978:2022, LME Cu-CATH-1, ASTM B115-10:2021) shows that impurity limits as low as 2 ppm (Bi) constrain the achievable share of secondary feed in closed-loop recycling. For a specific flash-smelting–refinery configuration, modeling indicates that secondary feed shares above approximately 30% may lead to impurity accumulation beyond the stated specification constraints unless low-impurity primary copper is introduced. This study introduces the Quality-Adjusted Circularity Indicator (QACI), a conceptual, specification-constrained indicator framework that applies a dilution factor fdil derived from a binary blending mass balance to adjust ISO 59020:2024 inflow-based circularity indicators using a feed-composition blending constraint anchored to Grade A specification limits. The QACI functions as a feed-composition screening indicator operating at the anode blending stage and does not represent a correction of the full electrorefining system. Parametric scenario analysis across six stylized impurity configurations shows that, at identical mass-based circularity (Cmass = 25%), the QACI ranges from 7.1% to 25.0%. This corresponds to a 1.3- to 3.5-fold difference between the mass-based and quality-adjusted indicator values under the stated feed-composition assumptions, illustrating the potential overestimation introduced when feed-quality constraints are not considered. This ratio quantifies the divergence between two indicator values under stylized conditions and should not be interpreted as a directly measured fold-difference in actual loop-closure performance. Positioned within the ISO 59020:2024 Annex C complementary method space, the QACI is positioned as a first-order screening approach of existing circularity metrics that may inform future research discussion of quality-differentiated approaches in EU secondary metals policy.