US Startup Introduces Eco-Friendly Solution for Copper Production

The demand for copper continues to surge globally, fueled by advancements in technology and the transition toward renewable energy solutions. However, traditional methods of copper production, particularly smelting, raise significant environmental concerns due to high energy consumption and pollutant emissions. Addressing these challenges, a US-based startup, Still Bright, has developed an innovative chemical process aimed at making copper extraction more sustainable.

Still Bright's approach centers on a water-based chemical process inspired by battery technology. Unlike conventional copper smelting, which requires extreme heat and results in the emission of sulfur-based gases, this new method operates at ambient temperatures and significantly reduces environmental impact. The process utilizes vanadium-based reactions to separate pure copper from its ore, allowing for a cleaner extraction with fewer harmful byproducts. This technique not only limits air pollution but also reduces the overall energy required for copper refinement.

The global copper market is under pressure as the demand is projected to rise by approximately 40 percent by 2040, particularly due to its essential role in electronics, electric vehicles, and renewable energy infrastructure. Despite copper being mined worldwide, a significant portion of raw copper concentrate is shipped to large smelting facilities, primarily in Asia, for final processing. This geographical concentration raises additional concerns over supply chain stability and environmental justice, as the negative impacts of smelting are often transferred to regions with less stringent environmental regulations.

Still Bright's process aims to decentralize copper refinement by enabling mines to process copper in a more environmentally responsible manner at or near extraction sites. The company's system involves reacting vanadium with copper-rich concentrate in a controlled reactor, resulting in solid copper and a liquid phase containing impurities. The copper-rich solid is then further purified using established industry techniques, ultimately achieving a purity exceeding 99 percent. Notably, the vanadium used in the process is recycled within the system, enhancing the method's sustainability.

While water-based chemical extraction methods for copper are not entirely new, Still Bright differentiates itself through its use of vanadium and the integration of a recycling step via electrolysis. After interacting with copper, the vanadium solution is regenerated using an electrolytic process, similar to the charging cycle of vanadium-flow batteries. This closed-loop approach minimizes waste and reduces the need for constant input of fresh chemicals.

Environmental benefits of Still Bright's technology include the elimination of high-temperature smelting and a significant reduction in the release of sulfur-containing gases, which are commonly associated with air pollution from conventional copper production. The process does produce hydrogen sulfide as a byproduct, but this material can be safely captured and converted into useful secondary products, mitigating its environmental risk. Proper management strategies are also in place for the handling of remaining sulfide minerals, to prevent contamination of groundwater and surrounding ecosystems.

Currently, Still Bright is conducting laboratory-scale testing in New Jersey, with plans to establish a pilot facility in Colorado capable of processing up to two tonnes of copper annually. The company aims to scale up its operations with a demonstration plant at a mining site, targeting a capacity of 500 tonnes per year within the next few years. Recent funding rounds have provided the resources necessary for further development and scaling of the technology.

The success of Still Bright's technology will depend on its ability to perform efficiently at an industrial scale and its acceptance within the traditionally conservative mining sector. Industry experts suggest that adoption will increase as the technology demonstrates its feasibility in real-world mining operations, offering a pathway toward greener copper production and a more resilient global supply chain.