Printed circuit board recycling: Physical processing and copper extraction by selective leaching

Screening of variables affecting the selective leaching of valuable metals from waste motherboards' PCBs

The presence of valuable and hazardous metals in waste printed circuit boards, especially, motherboards, makes their recovery necessary as implies great economic and environmental advantages and develops urban mining processes. Hence, this research is focused on the selective leaching of Cu, Pb, and Sn as base metals using nitric acid and hydrochloric acid and Au, Ag, and Pd as precious metals using thiourea and sodium thiosulfate from waste motherboards' PCBs in a sequential eco-friendly two-stage process. Previously, thiourea and sodium thiosulfate were used as leaching agents to investigate their applicability for the leaching of metals from PCBs in a single-stage process. Screening experimental design was applied to screen the variables affecting the leaching process in order to evaluate their impact on the recovery of metals and select the significant factors. The results demonstrated that base and precious metals can be leached appropriately in two consecutive stages compared to a single-stage process. Nitric acid was found to be a much more efficient agent to leach Cu and Pb in comparison with hydrochloric acid which was more suitable for the leaching of Sn. In the case of precious metals, higher amounts of Au were leached using thiourea, whereas sodium thiosulfate was able to leach more Pd. Roughly similar results were obtained for the leaching of Ag using these leaching agents. Nitric acid concentration, average particle size, temperature, and leaching time were found to be significant to maximize the leaching of Cu and Pb and minimize that for Au, Ag, and Pd in the first stage. Initial pH was the only variable influencing the second stage, in particular, Au leaching by thiourea.

Repair and recycling of PCBs and their components based on obsolescence index: a domestic electrical appliances case study

Population expansion and improving living standards, particularly in developed nations, have led to an increase in the usage of domestic electrical equipment, worldwide energy consumption, and CO2 emissions per capita. To limit the usage of non-reusable components and the amount of garbage that must be transferred at the end of a product's life cycle, longer-lasting electrical domestic appliances are a pillar of the circular economy. In recent years, the complexity of printed circuit boards (PCBs) used in the manufacture of modern electrical devices has increased, leading to an increase in device failures. This study focuses on the maintenance and recycling of domestic electrical appliance components and printed circuit boards. The proposed methodology for PCB repair is defined as a sequential quadratic programming (SQP) problem implemented in MATLAB environment and successfully tested to a variety of domestic appliances such as refrigerator, dishwasher and washing machine. The possibility of recycling metal parts of electronic components, which were replaced after PCBs' repair was also studied. Metals' percentage concentration of PCB electronic components for three customer's budgets considering metals and valuable metals recovery as given from the corresponding average metal recovery and calculated from different recycling procedures presented in the literature. The results of the proposed procedure in terms of valuable metals gave 38.4078 ppm of silver. We also compared the suggested procedure with other works in terms of environmental perspective considering four measures, namely the gross energy requirement (GER), the global warming potential (GWP), the acidification potential (AP), and the solid waste burden (SWB). In terms of economic perspective and considering the existence of silver (Ag) in the electronic components, the recommended method gave comparable amount of money. Finally, a comparison of different recycling works from a technical viewpoint is also conducted. Moreover, a reparability index of domestic electrical appliances is introduced to further quantify the results of the proposed algorithm.

A novel methodology for the estimation of failure behavior of "fair" smart meters and analysis of their circular economy chain

Electric power utilities are striving to address critical challenges such as energy consumption, material recovery, e-waste, procurement, and supplier working conditions. Currently, they are converting their old infrastructure into smart grids. The installation of smart meters is a key step in this process. Since a smart meter is an intelligent and modern measuring device that includes computer-aided measurements while also allowing intelligent management and determination of residential and industrial users' energy consumption and supply, their deployment in smart grids is of major importance. In this study, considering that the estimated number of smart meter units will be 188.12 million units by 2025, five different types of smart meters are used to estimate their failure behavior. We adopted the probability of smart meters' survival, considering the number of the components included in their PCBs, while the influence of their components follows an exponential distribution for a given lifetime. The meaning of the "fair" smart meter is introduced to solve critical concerns such as energy use, material consumption, e-waste, supplier sourcing, and labor conditions. To achieve the above targets, a circular economy chain analysis is implemented by dismantling the existing smart meters, classifying their materials into five primary groups and weighing them to obtain average values. Moreover, we calculate the average cost of the components using their equivalent market value as provided by stock markets to get the average weight of each component in terms of material cost. Finally, we introduce the "remanufacturing index" and the "reusing index" indices as procedure metrics to further quantify the circular economy chain results. The results show that the percentage of the reusing procedure in the "fair" smart meter circular economy chain is greater than the corresponding percentage of the remanufacturing procedure, while the percentage of the recycling procedure is increased as the recycling cost per unit, is also increased.

Two-Stage Leaching of PCBs Using Sulfuric and Nitric Acid with the Addition of Hydrogen Peroxide and Ozone

The paper presents the possibility of recovering metals from printed circuit boards (PCBs) of spent mobile phones using the hydrometallurgical method. Two-stage leaching of Cu(II), Fe(III), Sn(IV), Zn(II), Ni(II) and Pb(II) with H2SO4 (2 and 5 M) and HNO3 (2 M) with the addition of H2O2 (10 and 30%) and O3 (9 or 15 g/h) was conducted at various process conditions (temperature-313, 333 and 353 K, time-60, 120, 240, 300 min, type and concentration of leaching agent, type and concentration of oxidant, solid-liquid ratio (S/L)), allowing for a high or total metals leaching rate. The use of two leaching stages allows for the preservation of selectivity, separation and recovery of metals: in the first stage of Fe(III), Sn(IV) and in the second stage of the remaining tested metal ions, i.e., Cu(II), Zn(II), Ni(II) and Pb(II). Removing Fe from the tested PCBs' material at the beginning of the process eliminates the need to use magnetic methods, the purpose of which is to separate magnetic metal particles (ferrous) from non-magnetic (non-ferrous) particles; these procedures involve high operating costs. Since the leaching of Cu(II) ions with sulfuric(VI) acid practically does not occur (less than 1%), this allows for almost complete transfer of these ions into the solution in the second stage of leaching. Moreover, to speed up the process and not generate too many waste solutions, oxidants in the form of hydrogen peroxide and ozone were used. The best degree of leaching of all tested metal ions was obtained when 2 M sulfuric(VI) acid at 353 K was used in the 1st research stage, and 2 M nitric(V) acid and 9 g/h O3 at 298 K in the 2nd stage of leaching, which allowed it to be totally leached 100% of Fe(III), Cu(II), Sn(IV), Zn(II), Ni(II) and 90% Pb(II).

Relation between oxidation kinetics and reactant transport in an aqueous foam

HYPOTHESIS

Aqueous foams are expected to constitute exquisite particularly suitable reactive medium for the oxidation of metals, since the reactant H⁺ can be supplied through the continuous liquid phase, while the reactant O₂ can be transported through the gas bubbles.

EXPERIMENTS

To test this hypothesis, we investigated the oxidation of a metallic copper cylinder immersed in an aqueous foam. To study the relation between the transport of these reactants and the kinetics of the chemical reaction we use a forced drainage setup which enables us to control both the advection velocity of the H⁺ ions through the foam and the foam liquid fraction.

FINDINGS

We find experimentally that the mass of dissolved copper presents a maximum with the drainage flow rate, and thus with the foam liquid fraction. Modeling analytically the transfer of H⁺ and O₂ through the foams enables us to show that this non-monotonic behavior results from a competition between the advective flux of H⁺ ions and the unsteady diffusion of O₂ through the thin liquid films which tends to be slower as the area of the thin liquid films decreases with the drainage flow rate and the liquid fraction. This study shows for the first time how to optimize the foam structure and drainage flow in reactive foams in which the reactants are present both in the liquid and gaseous phases.

E-waste recycled materials as efficient catalysts for renewable energy technologies and better environmental sustainability

Waste from electrical and electronic equipment exponentially increased due to the innovation and the ever-increasing demand for electronic products in our life. The quantities of electronic waste (e-waste) produced are expected to reach 44.4 million metric tons over the next five years. Consequently, the global market for electronics recycling is expected to reach $65.8 billion by 2026. However, electronic waste management in developing countries is not appropriately handled, as only 17.4% has been collected and recycled. The inadequate electronic waste treatment causes significant environmental and health issues and a systematic depletion of natural resources in secondary material recycling and extracting valuable materials. Electronic waste contains numerous valuable materials that can be recovered and reused to create renewable energy technologies to overcome the shortage of raw materials and the adverse effects of using non-renewable energy resources. Several approaches were devoted to mitigate the impact of climate change. The cooperate social responsibilities supported integrating informal collection and recycling agencies into a well-structured management program. Moreover, the emission reductions resulting from recycling and proper management systems significantly impact climate change solutions. This emission reduction will create a channel in carbon market mechanisms by trading the CO2 emission reductions. This review provides an up-to-date overview and discussion of the different categories of electronic waste, the recycling methods, and the use of high recycled value-added (HAV) materials from various e-waste components in green renewable energy technologies.

A critical review of the pre-processing and metals recovery methods from e-wastes

E-wastes being potential sources of numerous valuable metals are promoted to undergo recycling and recovery under the umbrella of urban mining and circular economy. Thus, the present study provides a critical review of the technological details of different metal recycling processes, pre-treatment methods, and the advancements made in these techniques. Critical evaluation of different metal recovery techniques has also been presented based on the available life cycle assessment (LCA), techno-economic, and industrial-scale studies. The study revealed that the integrated metal recovery techniques serve better in terms of recovery efficiency and environmental performance than any single recovery technique. Also, scaling up of biometallurgical, electrochemical, and super critical fluid extraction methods needs to be promoted due to their better environmental performances.

Copper recovery through biohydrometallurgy route: chemical and physical characterization of magnetic (m), non-magnetic (nm) and mix samples from obsolete smartphones

The more modern electronics are, the smaller and complex printed circuit boards are. Thus, these materials are continually changed (physicochemically), increasing the copper concentrations in smartphones. In this sense, it is challenging to set standardized recycling processes to improve metal recovery. In addition, biohydrometallurgy is a clean and cheap process to obtain critical metals from low-grade sources and waste electronic equipment. Therefore, the aim of this work was to characterize, physicochemically, 21 PCBs from smartphones manufactured from 2010 to 2015, and then to recover the copper by Acidithiobacillus ferrooxidans (biohydrometallurgy). The PCBs were comminuted and separated into Magnetic (M), Nonmagnetic (NM) and without magnetic separation (MIX) samples. It was identified 217.8; 560.3 and 401.3 mg Cu/g of PCBs for M, NM and MIX samples, respectively. Regarding biohydrometallurgy, the culture media iron-supplemented (NM + Fe and MIX + Fe) increased the copper content by 2.6 and 7.2%, respectively, and the magnetic separation step was insignificant.

Potential and current practices of recycling waste printed circuit boards: A review of the recent progress in pyrometallurgy

Over the last few decades, a substantial amount of e-waste including waste printed circuit boards (WPCBs) has been produced and is accumulating worldwide. More recently, the rate of production has increased significantly, and this trend has raised some serious concerns regarding the need to develop viable recycling methods. The presence of other materials in the WPCBs, such as ceramics and polymers, and the multi-metal nature of WPCBs all contribute to the increased complexity of any recycling process. Among the viable techniques, pyrometallurgy, with the inherent ability to process the waste independent of its composition, is a promising candidate for both rapid and large-scale treatment. In the present study, firstly, the principles of the pyrometallurgical methods for WPCB recycling are discussed. Secondly, the different unit operations of thermochemical pretreatment including incineration, pyrolysis, and molten salt processing are reviewed. Thirdly, the smelting processes for the recovery of metals from WPCBs, as well as the issues surrounding slag formation and subsequent treatment are explained. Fourthly, alternative methods for the recovery of polymers and ceramics, in addition to metal recycling, are elucidated. Fifthly, emission control techniques and the potential for energy recovery are evaluated.

Metals extraction processes from electronic waste: constraints and opportunities

The skyrocketing demand and progressive technology have increased our dependency on electrical and electronic devices. However, the life span of these devices has been shortened because of rapid scientific expansions. Hence, massive volumes of electronic waste (e-waste) is generating day by day. Nevertheless, the ongoing management of e-waste has emerged as a major threat to sustainable economic development worldwide. In general, e-waste contains several toxic substances such as metals, plastics, and refractory oxides. Metals, particularly lead, mercury, nickel, cadmium, and copper along with some valuable metals such as rare earth metals, platinum group elements, alkaline and radioactive metal are very common; which can be extracted before disposing of the e-waste for reuse. In addition, many of these metals are hazardous. Therefore, e-waste management is an essential issue. In this study, we critically have reviewed the existing extraction processes and compared among different processes such as physical, biological, supercritical fluid technologies, pyro and hydrometallurgical, and hybrid methods used for metals extraction from e-waste. The review indicates that although each method has particular merits but hybrid methods are eco-friendlier with extraction efficiency > 90%. This study also provides insight into the technical challenges to the practical realization of metals extraction from e-waste sources.

Optimizing the Leaching Parameters and Studying the Kinetics of Copper Recovery from Waste Printed Circuit Boards

The study of copper (Cu) recovery is crucial for the entire recovery process of waste printed circuit boards (WPCBs), and Cu can be leached efficiently via a sulfuric acid-hydrogen peroxide (H₂SO₄-H₂O₂) system. To achieve high Cu recovery, it is important to evaluate the parameters of the leaching process and understand the Cu leaching kinetics. Applying statistical and mathematical techniques to the leaching process will further benefit the optimization of the Cu leaching parameters. Moreover, the leaching kinetics of Cu in the H₂SO₄-H₂O₂ solution is yet to be fully understood. Hence, in the present work, process parameters, such as temperature, H₂SO₄ and H₂O₂ concentrations, solid-liquid ratio, particle size, and stirring speed, were optimized statistically by the response surface methodology (RSM). The results showed that the leaching kinetics conformed to the Avrami model. The maximum Cu leaching efficiency was 99.47%, and it was obtained based on the following optimal conditions: 30.98 °C, 2.6 mol/L H₂SO₄, 1.87 mol/L H₂O₂, a solid-liquid ratio of 0.05 g/mL, 135 mesh, and 378 rpm. RSM was used for the optimization of the process parameters, and the leaching kinetics in this system was clarified. This study provides an important pathway for the investigation of other metal recoveries from WPCBs.

Selective Chelating Resin for Copper Removal and Recovery in Aqueous Acidic Solution Generated from Synthetic Copper-Citrate Complexes from Bioleaching of E-waste

This research focused on batch experiment using a new generation of chelating resins via an ion exchange process to describe the metabolic adsorption and desorption capacity onto iminodiacetic acid/Chelex 100, bis-pyridylmethyl amine/Dowex m4195, and aminomethyl phosphonic/Lewatit TP260 functional groups in bioleaching. The results showed that Dowex m4195 had the highest performance of adsorption capacity for copper removal in both H+-form and Na+-form. Results for Lewatit TP260 and Chelex 100 revealed lower adsorption performance than results for Dowex m4195. The investigation of desorption from chelating resins was carried out, and it was found that 2 M ammonium hydroxide concentration provided the best desorption capacity of about 64.86% for the H+-form Dowex m4195 followed by 52.55% with 2 M sulfuric acid. Lewatit with 2 M hydrochloric acid gave the best desorption performance in Na+-form while Chelex 100 using hydrochloric at 1 M and 2 M provided similar results in terms of the H+-form and Na+-form. As aspects of the selective chelating resins for copper (II) ions in aqueous acidic solution generated from synthetic copper-citrate complexes from bioleaching of e-waste were considered, H+-form Dowex m4195 was a good performer in adsorption using ammonium hydroxide for the desorption. However, chelating resins used were subsequently reused for more than five cycles with an acidic and basic solution. It can be concluded from these results that selective chelating resins could be used as an alternative for the treatment of copper (II) ions contained in e-waste or application to other divalent metals in wastewater for sustainable water and adsorbent reuse as circular economy.

Thermodynamic Rarity Assessment of Mobile Phone PCBs: A Physical Criticality Indicator in Times of Shortage

Rising prices in energy, raw materials, and shortages of critical raw materials (CRMs) for renewable energies or electric vehicles are jeopardizing the transition to a low-carbon economy. Therefore, managing scarce resources must be a priority for governments. To that end, appropriate indicators that can identify the criticality of raw materials and products is key. Thermodynamic rarity (TR) is an exergy-based indicator that measures the scarcity of elements in the earth’s crust and the energy intensity to extract and refine them. This paper uses TR to study 70 Mobile Phone (MP) Printed Circuit Boards (PCBs) samples. Results show that an average MP PCB has a TR of 88 MJ per unit, indicating their intensive use of valuable materials. Every year the embedded TR increases by 36,250 GWh worldwide -similar to the electricity consumed by Denmark in 2019- due to annual production of MP. Pd, Ta and Au embedded in MP PCBs worldwide between 2007 and 2021 contribute to 90% of the overall TR, which account for 75, 600 and 250 tones, respectively, and increasing by 11% annually. This, coupled with the short lifespan of MP, makes PCBs an important potential source of secondary resources.

Cobalt Recovery from Li-Ion Battery Recycling: A Critical Review

The increasing demand for Li-ion batteries for electric vehicles sheds light upon the Co supply chain. The metal is crucial to the cathode of these batteries, and the leading global producer is the D.R. Congo (70%). For this reason, it is considered critical/strategic due to the risk of interruption of supply in the short and medium term. Due to the increasing consumption for the transportation market, the batteries might be considered a secondary source of Co. The outstanding amount of spent batteries makes them to a core of urban mining warranting special attention. Greener technologies for Co recovery are necessary to achieve sustainable development. As a result of these sourcing challenges, this study is devoted to reviewing the techniques for Co recovery, such as acid leaching (inorganic and organic), separation (solvent extraction, ion exchange resins, and precipitation), and emerging technologies—ionic liquids, deep eutectic solvent, supercritical fluids, nanotechnology, and biohydrometallurgy. A dearth of research in emerging technologies for Co recovery from Li-ion batteries is discussed throughout the manuscript within a broader overview. The study is strictly connected to the Sustainability Development Goals (SDG) number 7, 8, 9, and 12.

Dismantling of Waste Printed Circuit Boards with the Simultaneous Recovery of Copper: Experimental Study and Process Modeling

The study was carried out with the aim to demonstrate the applicability of a combined chemical–electrochemical process for the dismantling of waste printed circuit boards (WPCBs) created from different types of electronic equipment. The concept implies a simple and less polluting process that allows the chemical dismantling of WPCBs with the simultaneous recovery of copper from the leaching solution and the regeneration of the leaching agent. In order to assess the performance of the dismantling process, various tests were performed on different types of WPCBs using the 0.3 M FeCl₃ in 0.5 M HCl leaching system. The experimental results show that, through the leaching process, the electronic components (EC) together with other fractions can be efficiently dismounted from the surface of WPCBs, with the parallel electrowinning of copper from the copper rich leaching solution. In addition, the process was scaled up for the dismantling of 100 kg/h WPCBs and modeled and simulated using process flow modelling software ChemCAD in order to assess the impact of all steps and equipment on the technical and environmental performance of the overall process. According to the results, the dismantling of 1 kg of WPCBs requires a total energy of 0.48 kWh, and the process can be performed with an overall low environmental impact based on the obtained general environmental indexes (GEIs) values.

Bioleaching metals from waste electrical and electronic equipment (WEEE) by Aspergillus niger: a review

In the twenty-first century, the increasing demand for electrical and electronic equipment (EEE) has caused its quick update and the shortening of its service life span. As a consequence, a large number of waste electrical and electronic equipment (WEEE) needs to be processed and recycled. As an environmentally friendly method, biometallurgy has received extensive attention in the disposal of WEEE in recent years. Aspergillus niger is an acid-producing fungus with a potential applicability to improve metals' recycling efficiency. This review article describes the latest statistical status of WEEE and presents the latest progress of various metallurgical methods involved in WEEE recycling for metal recovery. Moreover, based on the summary and comparison towards studies have been reported for bioleaching metals from WEEE by A. niger, the bioleaching mechanisms and the bioleaching methods are explained, as well as the effects of process parameters on the performance of the bioleaching process are also discussed. Some insights and perspectives are provided for A. niger to be applied to industrial processing scale.

Recovery of Metals from Heat-Treated Printed Circuit Boards via an Enhanced Gravity Concentrator and High-Gradient Magnetic Separator

The recovery and reuse of waste printed circuit boards (PCBs) has attracted more and more attention from global researchers, as recycling of waste PCB metals is of great significance to the rational utilization of metal material resources. This study puts forward a clean and economical method in which enhanced gravity separation and wet high-gradient magnetic separation were combined to recover waste PCBs with heat treatment at a temperature of 240 °C. The heat treatment could improve the metal liberation effect of the PCBs, and the thermal behavior was measured by thermogravimetric analysis (TGA). The pyrolysis of the non-metal fraction (NMF) began around 300 °C, and the glass transition temperature of epoxy resin was 135.17 °C. The enhanced gravity separation technique was used for the separation of metals and NMF under the compound force field. The metals grade of the gravity concentrates fraction (GRF) was 82.97% under the optimal conditions, and the metals recovery reached 90.55%. A wet high-gradient magnetic separator was applied to classify the GRF into magnetic (MA) and non-magnetic (NMA) fractions, which could achieve iron and copper enrichment. After the three stages combined process, the copper and iron grades of the NMA and MA fractions were 70.17% and 73.42%, and the recovery reached 74.02% and 78.11%, respectively.

Analysis of rejects from waste printed circuit board processing as an alternative fuel for the cement industry

Waste Printed circuit boards (PCBs) are one of the most valuable and recycled components of electronic waste due to the presence of precious metals such as copper, silver, gold and palladium. The rejects of the PCB recycling process, named non-metal fraction (NMF) have continuously been sent to landfills. Several researchers have proposed alternative use of NMF as secondary materials such as fillers in composites or as adsorbent. This study is focused on the potential application of the PCB recycling rejects as waste-derived fuel or alternative fuel in the cement industry. Approximately 2 million metric tonnes (Mt) of this waste was produced in 2014 globally and estimated to reach 6.5 million Mt in 2050. The presence of high organic matter in the NMF renders it useful as an alternative fuel. The organic content of the NMF could also potentially be increased using gravity separation and thus increasing its net calorific value. The study showed that the NMF could provide up to 21 MJ kg^-1 of heating value with low heavy metal and ash concentration. A comparison with other waste-derived fuel sources is also presented in the paper.

Electrochemical approaches for selective recovery of critical elements in hydrometallurgical processes of complex feedstocks

Critical minerals are essential for the ever-increasing urban and industrial activities in modern society. The shift to cost-efficient and ecofriendly urban mining can be an avenue to replace the traditional linear flow of virgin-mined materials. Electrochemical separation technologies provide a sustainable approach to metal recovery, through possible integration with renewable energy, the minimization of external chemical input, as well as reducing secondary pollution. In this review, recent advances in electrochemically mediated technologies for metal recovery are discussed, with a focus on rare earth elements and other key critical materials for the modern circular economy. Given the extreme heterogeneity of hydrometallurgically-derived media of complex feedstocks, we focus on the nature of molecular selectivity in various electrochemically assisted recovery techniques. Finally, we provide a perspective on the challenges and opportunities for process intensification in critical materials recycling, especially through combining electrochemical and hydrometallurgical separation steps.

Studies on leaching characteristics of electronic waste for metal recovery using inorganic and organic acids and base

In this paper, we report leaching of precious and scattered metals such as gold (Au), copper (Cu), nickel (Ni), zinc (Zn), iron (Fe), and lead (Pb) from printed circuit boards of scrap mobile phones by hydrometallurgical process using inorganic acid, organic acid and base. The amount of metals leached by different leachants are quantified using atomic absorption spectroscopy. Among various inorganic acids, aqua regia (mixture of nitric acid (HNO₃) and hydrochloric acid) is found to be the strongest leachant for most of the metals such as Zn (2.04 wt %), Fe (17.90 wt %), Ni (0.66 wt %), Pb (5.86 wt %) and Au (0.04 wt %). The basic leachant, ammonium thiosulphate is found to be very effective in leaching of Au (0.03125 wt %). The dissolution of Cu in HNO₃ gives the highest amount of Cu in the solvent, that is, ∼ 7.52 wt %. The metallic phases present in the electronic waste before and after leaching are identified by X-ray diffraction analysis. The microscopic structure has been studied using a scanning electron microscope which depicts erosion of the structure after leaching.

Pulsing Liquid Alloys for Nanomaterials Synthesis

Although it remains unexplored, the direct synthesis and expulsion of metals from alloys can offer many opportunities. Here, such a phenomenon is realized electrochemically by applying a polarizing voltage signal to liquid alloys. The signal induces an abrupt interfacial perturbation at the Ga-based liquid alloy surface and results in an unrestrained discharge of minority elements, such as Sn, In, and Zn, from the liquid alloy. We show that this can occur by either changing the surface tension or inducing a reversible redox reaction at the alloys' interface. The expelled metals exhibit nanosized and porous morphologies, and depending on the cell electrochemistry, these metals can be passivated with oxide layers or fully oxidized into distinct nanostructures. The proposed concept of metal expulsion from liquid alloys can be extended to a wide variety of molten metals for producing metallic and metallic compound nanostructures for advanced applications.

Copper and Antimony Recovery from Electronic Waste by Hydrometallurgical and Electrochemical Techniques

A strategy for the efficient recovery of highly pure copper and antimony metals from electronic waste (e-waste) was implemented by the combination of hydrometallurgical and electrochemical processes. The focus is on copper recovery as the main component in the leached solution, whereas the antimony recovery process was established as a purification step in order to achieve a highly pure copper deposit. The strategy includes mechanical methods to reduce the size of the wasted printed circuit boards to enhance the efficiency of antimony and copper lixiviation via ferric chloride in acidic media (0.5 M HCl) followed by an electrowinning process. In order to establish the best parameters for copper electrowinning, the leached solution was characterized by cyclic voltammetry and cathodic polarization. Then, an electrochemical reactor with a rotating cylinder electrode was used to evaluate the copper concentration decay, the cathodic current efficiency, the specific energy consumption, and mass-transfer coefficient. Furthermore, antimony was recovered via precipitation by a pH modification in accordance with the Pourbaix diagram. Under this methodology, two valuable products from the e-waste were recovered: a 96 wt % pure copper deposit and 81 wt % pure antimony precipitate. The strategy for recovery of other metal ions, such as lead, present in the e-waste at high concentrations will be reported in further works.

Recovery of metals from waste printed circuit boards by selective leaching combined with cyclone electrowinning process

This paper provides a benign process that realized the metals separation and recovery from wPCBs in an efficient and low cost way. The chemical active order and potential-pH diagram of the metals enlightened us to apply stepwise leaching to selective separation of the metals from the wPCBs. The results indicated that the selective separation of Fe, Al, Zn; Sn and Cu can be achieved by the dilute sulfuric acid leaching, displacement leaching using copper sulphate and sulfuric acid leaching with air-oxidization, respectively. Under the optimal conditions, the leaching efficiency of Fe, Al, Zn, Sn and Cu were 92.59%, 90.51%, 89.73%, 1.44% and 0.82%, respectively, in the dilute sulfuric acid leaching. In the displacement leaching, the displacement efficiency of Sn was as high as 95.20%, with little Cu leached. The data of sulfuric acid leaching with air-oxidization experiments shows that the leaching efficiency of Cu reached 95.72%. In order to recover the Sn and Cu in the solutions, the hydrolysis precipitation and cyclone electrowinning were introduced. With these techniques, 92.75% Sn was precipitated and the smooth cathode copper (purity 99.98%) was obtained with the current efficiency was 94.96%. Moreover, the analysis of the mass distribution about the process demonstrated that the H⁺ and Cu²⁺ were consumed, but also produced in different procedure, that means the process is a simple and eco-friendly technology, not only due to its high recovery efficiency, but also high reagents recyclable.

Electrochemical extraction of tin and copper from acid leachate of printed circuit boards using copper electrodes

This paper presents new results for the recycling of electronic waste, specifically those from printed circuit boards (PCBs) of obsolete computers of the Federal University of Rio Grande do Norte. The main objective of this study is the comprehension of the extraction process of tin and cop per from PCBs by a hydrometallurgical route followed by electrodeposition using copper electrodes. PCBs powder were leached using 1N HNO₃ and 3N HCl (aqua regia) aqueous solutions. The process permitted the extraction of all tin present on the PCBs. The electrodeposition processes were performed with currents from 0.5 to 1.5 A, at a constant time of 60 min, with and without mechanical stirring, and with different concentrations of leachate. The results showed that diluting the leachate favors the extraction of tin from the solution. At certain conditions we were able to extract approximately 100% of the tin, copper and lead present in the leachate.

Selective synthesis of CuNi alloys using waste PCB and NiMH battery

The aim of this study is to establish the potential novel approach for the selective synthesis of copper-nickel (CuNi) alloys using two waste streams, printed circuit board (PCB) and nickel-metal hydride (NiMH) batteries. A thermal route is established to synthesise CuNi alloys by using waste PCB, simultaneously as a Cu source and reducing agent from C-bearing polymer and waste NiMH batteries as Ni source. Thermal transformation and reduction studies were carried out at 1500 °C under an inert atmosphere. Initial characterization of raw materials was conducted in detail using various analytical techniques. Synthesised CuNi alloys were confirmed with ICP, EDS and XRD analyses. Material ratios of 75-25 wt% and 50-50 wt% of NiMH battery and PCB waste was considered and these range of compositions of e-waste, as raw materials, minimised the slag generation and optimised Ni recovery. Concentration of Nickel in the synthesised alloys was 20-30 wt%. Reduction extent of nickel oxide using PCB as reductant was confirmed by off-gas analysis. This approach has the potential to be implemented in selective synthesis of CuNi alloys instead of using conventional ores/reductant, to achieve target composition of alloys as per application requirements including marine/automotive/electronic industries. This novel approach promises significant benefits to divert e-wastes from landfill and provide sustainable solution for future metal alloy security.

A novel indole-based conjugated microporous polymer for highly effective removal of heavy metals from aqueous solution via double cation–π interactions

A novel indole-based conjugated microporous polymer (PTIA) with three coplanar indole units, designed and synthesized by an oxidative coupling reaction, was utilized as a platform for removing heavy metals.

Concentration of precious metals from waste printed circuit boards using supergravity separation

Printed circuit boards (PCBs) comprise valuable metals, precious metals, and hazardous materials. Thus, they are considered both attractive secondary sources of metals and environmental pollutants. This study is based on the selective separation of Pb-Sn, Sn-Cu, and Cu-Zn alloys, where supergravity separation was used to concentrate precious metals (i.e., Ag, Au, and Pd) from PCBs in Cu-Zn alloy and final residue. The temperature and gravity coefficient were found to have great influence on the concentration of precious metals in said alloy and residue. At the optimized temperature of 1300 °C, gravity coefficient of 1000, and separation time of 5 min, the Ag, Au, and Pd contents in the Cu-Zn alloy increased by 1.65, 2.05, and 1.54 times, respectively, compared to their concentrations in the original PCBs, while those in the final residue increased by 0.63, 1.02, and 2.62 times, respectively. By combining an appropriate hydrometallurgical process with the present supergravity separation and concentration of precious metals, this clean and efficient process provides a new pathway to recycle valuable metals and prevent environmental pollution by PCBs.

Physical and thermal processing of Waste Printed Circuit Boards aiming for the recovery of gold and copper

The recovery of electronic waste to obtain secondary raw materials is a subject of high relevance in the context of circular economy. Accordingly, the present work relies on the evaluation of mining separation/concentration techniques (comminution, size screening, magnetic separation and gravity concentration) alone as well as combined with thermal pre-treatment to recover gold and copper from Waste Printed Circuit Boards. For that purpose, Waste Printed Circuit Boards were subjected to physical processing (comminution, size screening in 6 classes from <0.425 mm to > 6.70 mm, magnetic separation and gravity concentration) alone and combined with thermal treatment (200-500 °C), aiming the recovery of gold and copper. Mixed motherboards and graphic cards (Lot 1 and 3) and highly rich components (connectors separated from memory cards, Lot 2) were analyzed. Gold and copper concentrations were determined before and after treatment. Before treatment, concentrations from 0.01 to 0.6 % wt. and from 9 to 20 % wt. were found for gold and copper respectively. The highest concentrations were observed in the size fractions between 0.425 and 1.70 mm. The highest copper concentration was around 35 % wt. (class 0.425-0.85 mm) and when analyzing memory card connectors alone, gold concentrations reached almost 2% in the same class, reflecting the interest of separating such components. The physical treatment alone was more effective for Lot 1/3, compared to Lot 2, allowing recoveries of 67 % wt. and 87 % wt. for gold and copper respectively, mostly due to differences in particles size and shape. The thermal treatment showed unperceptive influence on gold concentration but significant effect for copper concentration, mostly attributed to the size of the copper particles. Concentrations increased in a factor of around 10 when the thermal treatment was performed at 300 °C for the larger particles (1.70-6.70 mm); the best results were obtained at 400 °C for the other sizes, when the highest rate of thermal decomposition of the material occurred.

Investigation and evaluation of the detachment of printed circuit boards from waste appliances for effective recycling

To establish an effective recycling process for waste appliances, the process of recovering printed circuit boards (PCBs) containing valuable elements in comminution was investigated and evaluated. The present study performed comminution tests using three different types of waste appliances: smartphones, microwave ovens and electrical rice cookers. Comminution tests showed that a drum-type agitation mill operated at a mid-range rotation speed could achieve a relatively high recovery ratio of PCBs and inhibit excessive breakage of PCBs. Following these experiments, simulations using the discrete element method with a particle-based rigid-body model were conducted to evaluate the comminution performance of the drum-type agitation mill. Experimental and simulation results confirm that the processes of detachment of PCBs from waste appliances and subsequent breakage can be expressed by kinetic equations related to collision energy. It is concluded from these results that the kinetic equations obtained in experiments and simulations can be used to evaluate the recovery process of PCBs from waste appliances.

Recovery of base metals, silicon and fluoride ions from mobile phone printed circuit boards after leaching with hydrogen fluoride and hydrogen peroxide mixtures

The recovery of copper, nickel, zinc, silicon, iron, aluminum, tin and fluoride ions from fluoride leach liquors of non-ground printed circuit boards (PCBs) from mobile phones is described in detail. These PCBs were leached with HF + H₂O₂ mixtures after previous treatment with 6 mol L^-1 NaOH (removal of the solder mask). A combination of solvent extraction (SX) and precipitation techniques was used. 99.5 wt% zinc, copper and nickel, in this order, were extracted in one stage (Zn, Ni) or two stages (Cu) with di-2-ethylhexylphosphoric acid (D2EHPA) diluted in kerosene (25 °C, A/O = 1 v/v) after adjusting the pH of the leachate. They were easily stripped by aqueous H₂SO₄. Iron, aluminum and tin did not interfere because they were masked by fluoride ions. Iron and aluminum were precipitated together as Na₃FeF₆ + Na₃AlF₆ by careful addition of aqueous NaOH. Silicon, tin and fluoride ions were recovered together (Na₂SiF₆ + Na₂SnF₆ + NaF) by careful evaporation of the aqueous solution after SX of nickel. The tin salt was leached from this solid by absolute ethanol. High HF concentration (10 mol L^-1) in the leachant affected SX of Cu(II) and precipitation of iron/aluminum flurocomplexes since some NaF partially precipitated at acidic pH.

Fungal bioleaching of WPCBs using Aspergillus niger: Observation, optimization and kinetics

In this study, Aspergillus niger (A. niger) as an environmentally friendly agent for fungal bioleaching of waste printed circuit boards (WPCBs) was employed. D-optimal response surface methodology (RSM) was utilized for optimization of the bioleaching parameters including bioleaching method (one step, two step and spent medium) and pulp densities (0.5 g L^-1 to 20 g L^-1) to maximize the recovery of Zn, Ni and Cu from WPCBs. According to the high performance liquid chromatography analysis, citric, oxalic, malic and gluconic acids were the most abundant organic acids produced by A.niger in 21 days experiments. Maximum recoveries of 98.57% of Zn, 43.95% of Ni and 64.03% of Cu were achieved based on acidolysis and complexolysis dissolution mechanisms of organic acids. Based on the kinetic studies, the rate controlling mechanism for Zn dissolution at one step approach was found to be diffusion through liquid film, while it was found to be mixed control for both two step and spent medium. Furthermore, rate of Cu dissolution which is controlled by diffusion in one step and two step approaches, detected to be controlled by chemical reaction at spent medium. It was shown that for Ni, the rate is controlled by chemical reaction for all the methods studied. Eventually, it was understood that A. niger is capable of leaching 100% of Zn, 80.39% of Ni and 85.88% of Cu in 30 days.

Status of electronic waste recycling techniques: a review

The increasing use of electrical and electronic equipment leads to a huge generation of electronic waste (e-waste). It is the fastest growing waste stream in the world. Almost all electrical and electronic equipment contain printed circuit boards as an essential part. Improper handling of these electronic wastes could bring serious risk to human health and the environment. On the other hand, proper handling of this waste requires a sound management strategy for awareness, collection, recycling, and reuse. Nowadays, the effective recycling of this type of waste has been considered as a main challenge for any society. Printed circuit boards (PCBs), which are the base of many electronic industries, are rich in valuable heavy metals and toxic halogenated organic substances. In this review, the composition of different PCBs and their harmful effects are discussed. Various techniques in common use for recycling the most important metals from the metallic fractions of e-waste are illustrated. The recovery of metals from e-waste material after physical separation through pyrometallurgical, hydrometallurgical, or biohydrometallurgical routes is also discussed, along with alternative uses of non-metallic fraction. The data are explained and compared with the current e-waste management efforts done in Egypt. Future perspectives and challenges facing Egypt for proper e-waste recycling are also discussed.

Electronic wastes

E-waste amount is growing at about 4% annually, and has become the fastest growing waste stream in the industrialized world. Over 50 million tons of e-waste are produced globally each year, and some of them end up in landfills causing danger of toxic chemicals leakage over time. E-waste is also sent to developing countries where informal processing of waste electrical and electronic equipment (WEEE) causes serious health and pollution problems. A huge interest in recovery of valuable metals from WEEE is clearly visible in a great number of scientific, popular scientific publications or government and industrial reports.

Composition and Elution Behavior of Various Elements from Printed Circuit Boards, Cathode-ray Tube Glass, and Liquid-crystal Displays in Waste Consumer Electronics

The contents and elution behavior of metals in consumer electronics parts were determined so as to understand their maximum environmental risk. Elements contained most in printed-circuit boards were Cu, Si, Br, Ca, Al, Sn, Pb, Sb, Ba, Fe, Ni, Ti, and Zn; in cathode-ray tube glass were Si, Pb, Ba, Sr, Zn, Zr, Ca, and Sb; in arsenic contained liquid-crystal displays were Si, Ca, Sr, Ba, As, and Fe; and in antimony contained liquid-crystal displays were Si, Ba, Ca, Sb, Sr, Fe, and Sn. The elements eluted most from printed-circuit boards were Zn, Pb, and Cu; from cathode-ray tube glass were Pb, Zn, B, Ba, and Si; and from liquid-crystal displays were B and Si, and the toxic As and Sb. The amount eluted was greatest at acidic pH. It was revealed that officially recommended 6-h-shaking with a pure water test was insufficient to understand the real environmental risk of waste electronics.

High temperature investigations on optimising the recovery of copper from waste printed circuit boards

High temperature pyrolysis investigations were carried out on waste printed circuit boards (PCBs) in the temperature range 800-1000°C under inert conditions, with an aim to determine optimal operating conditions for the recovery of copper. Pyrolysis residues were characterized using ICP-OES analysis, SEM/EDS and XRD investigations. Copper foils were successfully recovered after pyrolysis at 800°C for 10-20 min; the levels of Pb and Sn present were found to be quite low and these were generally present near the foil edges. The relative proportions of Pb and Sn became progressively higher at longer heating times due to enhanced diffusion of these molten metals in solid copper. While a similar behaviour was observed at 900°C, the pyrolysis at 1000°C resulted in copper forming Cu-Sn-Pb alloys; copper foils could no longer be recovered. Optimal conditions were identified for the direct recovery of copper from waste PCBs with minimal processing. This approach is expected to make significant contributions towards enhancing material recovery, process efficiency and the environmental sustainability of recycling e-waste. Pyrolysis at lower temperatures, short heating times, coupled with reductions in process steps are expected to significantly reduce energy consumption and pollution associated with the handling and processing of waste PCBs.

A novel approach for recovery of metals from waste printed circuit boards and simultaneous removal of iron from steel pickling waste liquor by two-step hydrometallurgical method

Waste printed circuit boards (WPCBs) and steel pickling waste liquor (SPWL) have received extensive attention in recent years because of its harmfulness and resource. In this work, two-step leaching process was carried out by using SPWL as the leaching agent. A series of continuously domesticated bacteria were used for bioleaching and the bacterial strain was identified as Acidithiobacillus ferrooxidans (A. ferrooxidans) by 16S rDNA gene sequence analysis. The vast majority of the metals in WPCBs were recovered by two-step leaching, such as Cu, Pb, Zn, Sn, Al, Ni. Meanwhile, a large amount of iron was removed from SPWL, which greatly reduces the burden of the subsequent treatment. Pulp density and pH were optimized to achieve maximum recovery of copper and simultaneous removal of iron in bioleaching. It was found that the optimum conditions were pulp density 60 g/L and pH 0.5-1.0. Nearly 100% of copper was recovered and 51.94% of iron was removed under optimum conditions. The kinetic experiments showed that the rate of copper leaching was controlled by external diffusion rather than internal diffusion, because the acidic environment of the leachate prevented the formation of the precipitate and maintained it in a smaller size.

Effect of temperature on copper, iron and lead leaching from e-waste using citrate solutions

E-waste is a potential source of large quantities of metals. The ability of citrate solutions to recover base metals from these materials has been demonstrated. In the present study, the effect of the temperature on base metal leaching capacity by the citrate solutions is determined. The material employed consisted of a mechanically prepared, gravity concentrated e-waste, with a metallic content greater than 90%. The leaching conditions were selected based on previous research performed by the authors (0.5 M sodium citrate, pH 4.5 and 20 g per liter e-waste concentrate). Leaching tests were performed at temperatures between 0° and 70 °C. The initial leaching rates for the three metals increased with temperature. However, these tapered off with time for temperatures above 30 °C, which can be associated to citrate destruction.

New technology for recovering residual metals from nonmetallic fractions of waste printed circuit boards

Recycling of waste printed circuit boards is important for environmental protection and sustainable resource utilization. Corona electrostatic separation has been widely used to recycle metals from waste printed circuit boards, but it has poor separation efficiency for finer sized fractions. In this study, a new process of vibrated gas-solid fluidized bed was used to recycle residual metals from nonmetallic fractions, which were treated using the corona electrostatic separation technology. The effects of three main parameters, i.e., vibration frequency, superficial air flow velocity, and fluidizing time on gravity segregation, were investigated using a vibrating gas-solid fluidized bed. Each size fraction had its own optimum parameters. Corresponding to their optimal segregation performance, the products from each experiment were analyzed using an X-ray fluorescence (XRF) and a scanning electron microscope (SEM) equipped with an energy dispersive spectrometer (EDS). From the results, it can be seen that the metal recoveries of -1+0.5mm, -0.5+0.25mm, and -0.25mm size fractions were 86.39%, 82.22% and 76.63%, respectively. After separation, each metal content in the -1+0.5 or -0.5+0.25mm size fraction reduced to 1% or less, while the Fe and Cu contents are up to 2.57% and 1.50%, respectively, in the -0.25mm size fraction. Images of the nonmetallic fractions with a size of -0.25mm indicated that a considerable amount of clavate glass fibers existed in these nonmetallic fractions, which may explain why fine particles had the poorest segregation performance.

Evaluating waste printed circuit boards recycling: Opportunities and challenges, a mini review

Rapid generation of waste printed circuit boards has become a very serious issue worldwide. Numerous techniques have been developed in the last decade to resolve the pollution from waste printed circuit boards, and also recover valuable metals from the waste printed circuit boards stream on a large-scale. However, these techniques have their own certain specific drawbacks that need to be rectified properly. In this review article, these recycling technologies are evaluated based on a strength, weaknesses, opportunities and threats analysis. Furthermore, it is warranted that, the substantial research is required to improve the current technologies for waste printed circuit boards recycling in the outlook of large-scale applications.

Waste Printed Circuit Board (PCB) Recycling Techniques

With the development of technologies and the change of consumer attitudes, the amount of waste electrical and electronic equipment (WEEE) is increasing annually. As the core part of WEEE, the waste printed circuit board (WPCB) is a dangerous waste but at the same time a rich resource for various kinds of materials. In this work, various WPCB treatment methods as well as WPCB recycling techniques divided into direct treatment (landfill and incineration), primitive recycling technology (pyrometallurgy, hydrometallurgy, biometallurgy and primitive full recovery of NMF-non metallic fraction), and advanced recycling technology (mechanical separation, direct use and modification of NMF) are reviewed and analyzed based on their advantages and disadvantages. Also, the evaluation criteria are discussed including economic, environmental, and gate-to-market ability. This review indicates the future research direction of WPCB recycling should focus on a combination of several techniques or in series recycling to maximize the benefits of process.

Comparative assessment of metallurgical recovery of metals from electronic waste with special emphasis on bioleaching

Waste electrical and electronic equipment (WEEE) or electronic waste (e-waste) is one of the fastest growing waste streams in the urban environment worldwide. The core component of printed circuit board (PCB) in e-waste contains a complex array of metals in rich quantity, some of which are toxic to the environment and all of which are valuable resources. Therefore, the recycling of e-waste is an important aspect not only from the point of waste treatment but also from the recovery of metals for economic growth. Conventional approaches for recovery of metals from e-waste, viz. pyrometallurgical and hydrometallurgical techniques, are rapid and efficient, but cause secondary pollution and economically unviable. Limitations of the conventional techniques have led to a shift towards biometallurgical technique involving microbiological leaching of metals from e-waste in eco-friendly manner. However, optimization of certain biotic and abiotic factors such as microbial species, pH, temperature, nutrients, and aeration rate affect the bioleaching process and can lead to profitable recovery of metals from e-waste. The present review provides a comprehensive assessment on the metallurgical techniques for recovery of metals from e-waste with special emphasis on bioleaching process and the associated factors.

Triboelectric separation technology for removing inorganics from non-metallic fraction of waste printed circuit boards: Influence of size fraction and process optimization

Removing inorganics from non-metallic fraction (NMF) of waste printed circuit boards (WPCBs) is an effective mean to improve its usability. The effect of size fraction on the triboelectric separation of NMF of WPCBs was investigated in a lab triboelectric separation system and the separation process was optimized in this paper. The elements distribution in raw NMF collected from typical WPCBs recycling plant and each size fraction obtained by sieving were analyzed by X-ray fluorescence (XRF). The results show that the main inorganic elements in NMF are P, Ba, Mn, Sb, Ti, Pb, Zn, Sn, Mg, Fe, Ca, Cu, Al and Si. The inorganic content of each size fraction increased with the size decreasing. The metal elements are mainly distributed in -0.2mm size fraction, and concentrated in middle product of triboelectric separation. The loss on ignition (LOI) of positive product and negative product is higher than that of the middle product for the -0.355mm size fraction, while the LOI presents gradually increasing trend from negative to positive plate for the +0.355mm size fraction. Based on the separation results and mineralogical characterizations of each size fraction of NMF, the pretreatment process including several mineral processing operations was added before triboelectric separation and better separation result was obtained.

Closed circuit recovery of copper, lead and iron from electronic waste with citrate solutions

An integral closed circuit hydrometallurgical process is presented for base metal recovery from electronic waste. The leaching medium consists of a sodium citrate solution, from which base metals are retrieved by direct electrowinning, and the barren solution is recycled back to the leaching stage. This leaching-electrowinning cycle was repeated four times. The redox properties of the fresh citrate solution, as well as the leach liquors, were characterized by cyclic voltammetry to determine adequate conditions for metal reduction, as well as to limit citrate degradation. The leaching efficiency of electronic waste, employing the same solution after four complete cycles was 71, 83 and 94% for copper, iron and lead, respectively, compared to the original leach with fresh citrate solution.