Key factors of eddy current separation for recovering aluminum from crushed e-waste

Elemental characterization of electronic waste: a review of research methodologies and applicability to the practice of e-waste recycling

Economic and environmental considerations have elucidated research interests on the best approach to managing electronic waste (e-waste), which has increasing social, environmental, and economic impacts. Proper e-waste managementis essential for resource recovery, environmental sustainability, and public health protection, and effective management of e-waste necessitates analytical techniques to assess and characterize their elemental composition. Despite expansive literature published on the topic of e-waste, there is scarce coverage of the various analytical techniques employed to characterize the inorganic contents of e-waste. This review discusses the various e-waste characterization techniques used in studies published between 2013 and 2023. Specifically, this review covers the analytical approaches employed to characterize the inorganic content of e-waste, the electronic devices or their components analyzed, the elements identified, the sample preparation methods adopted, and the merits and demerits of the analytical procedures. This review highlights the disparate approaches to e-waste characterization and the need for reliable and repeatable e-waste analysis and sample preparation methods.

A biogenic hydrogel to recover Au(III) from electronic waste

In the course of this investigation, we undertook the contemplation of a green chemistry paradigm with the express intent of procuring valuable metal, namely gold, from electronic waste (e-waste). In pursuit of this overarching objective, we conceived a procedural framework consisting of two pivotal stages. As an initial stage, we introduced a physical separation procedure relying on the utilization of the Eddy current separator, prior to embarking on the process of leaching from e-waste. Subsequent to the partitioning of metals from the non-metal constituents of waste printed circuit boards (PCB), we initiated an investigation into the hydrogel derived from basil seeds (Ocimum basilicum L.), utilizing it as a biogenic sorbent medium. The thorough characterization of hydrogel extracted from basil seeds involved the application of an array of analytical techniques, encompassing FTIR, XRD, SEM, and BET. The batch sorption experiments show more than 90% uptake in the pH range of 2-5. The sorption capacity of the hydrogel material was evaluated as 188.44 mg g-1 from the Langmuir Isotherm model. The potential interference stemming from a spectrum of other ions, encompassing Al, Cu, Ni, Zn, Co, Cr, Fe, Mn, and Pb was systematically examined. Notably, the sole instance of interference in the context of adsorption of gold ions was observed to be associated with the presence of lead. The application of the hydrogel demonstrated a commendable efficiency in the recovery of Au(III) from the leached solution derived from the waste PCB.

Generation mechanism and empirical model of eddy current force and torque in drum-type eddy current separation

Enhancing the recovery efficiency of non-ferrous metals in eddy current separation is of great significance. In this study, the accuracy of the simulation model was verified by comparing the eddy current force. The transformation mechanism of the Lorentz forces into the eddy current force and torque in non-ferrous metal particles was revealed by analyzing various physical fields. Then, the influence of magnetic field parameters on eddy current, eddy current force, and torque was studied. It shows that the eddy current force and torque are affected by the vector gradient of the magnetic field and the magnetic flux density, respectively. Additionally, the time derivative of the magnetic field impacts the magnitude of the eddy current force and torque by controlling the eddy current. On this basis, the empirical models of eddy current force and torque were established by similarity theory. The results obtained can improve and expand the application of eddy current separation.

Process development options for electronic waste fractionation to achieve maximum material value recovery

Revised legislation and bans on imports of waste electrical and electronic equipment (WEEE) into many Asian countries for treatment are driving the need for more efficient WEEE fractionation in Europe by expanding the capacity of treatment plants and improving the percentage recovery of materials of economic value. Data from a key stakeholder survey and consultation are combined with the results of a detailed literature survey to provide weighted matrix input into multi-criteria decision analysis calculations to carry out the following tasks: (a) assess the relative importance of 12 process options against the 6 industry-derived in-process economic potential criteria, that is, increase in product quality, increase in recycling rate, increase in process capacity, decrease in labour costs, decrease in energy costs and decrease in disposal costs; and (b) rank 25 key technologies that have been selected as being the most likely to benefit the efficient sorting of WEEE. The results indicate that the first stage in the development of any total system to achieve maximum economic recovery of materials from WEEE has to be the selection and application of appropriate fractionation process technologies to concentrate valuable components such as critical metals into the smallest possible fractions to achieve their recovery while minimising the disposal costs of low-value products. The stakeholder-based study has determined the priority for viable technical process developments for efficient WEEE fractionation and highlighted the economic and technical improvements that have to be made in the treatment of WEEE.

A review on recent advancements in recovery of valuable and toxic metals from e-waste using bioleaching approach

This review is intent on the environmental pollution generated from printed circuit boards and the methods employed to retrieve valuable and hazardous metals present in the e-wastes. Printed circuit boards are the key components in the electronic devices and considered as huge e-pollutants in polluting our surroundings and the environment as a whole. Composing of toxic heavy metals, it causes serious health effects to the plants, animals and humans in the environment. A number of chemical, biological and physical approaches were carried out to recover the precious metals and to remove the hazardous metals from the environment. Chemical leaching is one of the conventional PCBs recycling methods which was carried out by using different organic solvents and chemicals. Need of high cost for execution, generation of secondary wastes in the conventional methods, forces to discover the advanced recycling methods such as hydrometallurgical, bio-metallurgical and bioleaching processes to retrieve the valuable metals generate through e-wastes. Among them, bioleaching process gain extra priority due to its higher efficiency of metal recovery from printed circuit boards. There are different classes of microorganisms have been utilized for precious metal recovery from the PCBs through bioleaching process such as chemolithoautotrophy, heterotrophy and different fungal species including Aspergillus sp. and Penicillium sp. The current status and scope for further studies in printed circuit boards recycling are discussed in this review.

Qualitative and quantitative assessment of waste generation in a refrigerator-manufacturing plant based on a waste tree and mass balance

In this study, wastes originating at each production station during refrigerator manufacturing were identified and classified based on a waste tree. A mass balance study revealed a total waste production factor of 0.046 kg/kg of a product of which 75.3%, 23.9%, and 0.8% were non-hazardous wastes (NHWs), packaging wastes (PWs), and hazardous wastes (HWs), respectively. Wastes produced during refrigerator manufacturing were grouped under 35 different waste codes. Waste codes that contributed more than 5% by weight were 15 02 02 (contaminated absorbent material), 15 01 10 (contaminated packaging), 16 02 13 (electronic cards), 07 02 14 (polyol) and 08 05 01 (isocyanates), 19 08 13 (treatment sludge), 16 02 15 (capacitors), and 13 01 13 (hydraulic oil) for HWs, 12 01 01 (ferrous metal), and 16 02 16 (components) for NHWs, and, finally, 15 01 03 (wooden), 15 01 01 (paper&cardboard), and 15 01 02 (plastic) for PWs over 5 years. Scrap costs were used as a surrogate to determine production stages that generated high amounts of metal and plastic wastes. Logarithmically, increasing and decreasing trends were observed for PWs and NHWs over the study period, respectively. HW amounts did not exhibit a statistically significant trend. Twenty-eight BATs (best available techniques) were identified that could be applied in refrigerator manufacturing for waste minimization and management. Among those, 8 of them were proposed for further improvement for waste management in the facility.

Process optimization for acidic leaching of rare earth elements (REE) from waste electrical and electronic equipment (WEEE)

E-waste (EW) from discarded electrical and electronic devices is a potential source of rare earth elements (REEs) that might be recovered from urban and industrial wastes. REEs are essential raw materials for emerging and high technologies. China currently dominates global REE production with a proportion of 97%. To increase the independence of REE supply and eliminate the environmental impacts related to REE mining, methods for an efficient REE recovery from secondary sources like EW are needed. In this work, we examine improvements in pre-treatment and acidic leaching processes to recover REEs and other valuable metals. EW was crushed and ground prior to the sieving. The materials obtained were then subjected to acid leaching. The parameters used to optimize the conditions for leaching were as follows: acid type (HCl, HNO₃, and aqua regia), particle size, and waste-to-acid ratio. The maximum leaching efficiency was obtained from the ground, sieved, and undersized part of e-waste by using HCl with a W:A of 12.5 mg/mL. The total REE concentration was 435 mg/kg. Several treatment scenarios are identified with promise for improving REE recovery at full scale in EW recovery plants and thereby advancing goals for a sustainable, circular economy.

Recycling of electrode materials from spent lithium-ion power batteries via thermal and mechanical treatments

This study developed a physical separation process that recovers active cathode materials from current collectors in spent lithium-ion power batteries (LIBs). The physical separation process, implemented via thermal and mechanical treatments, was examined based on cohesive zone models (CZMs) and verified by physical separation experiments. The most efficient condition was determined by optimising the key parameters (temperature and time) of selective heating. Among several mechanical separation methods, high-speed shearing best separates positive electrode materials into active cathode materials (LiFePO₄) and current collectors (Al fragments). The separation effect was verified by computing the dissociation rate and microscopic observation of the separated materials. The feasibility and efficiency of the above process were assessed in a work-of-force analysis, flow field simulation, high-speed crushing experiment and material property analysis. The above analyses realised a feasible, efficient and environmentally friendly separation route without changing the chemical structure and properties of the electrode materials. Under non-high (energy-conserving) temperature conditions, the LiFePO₄ dissociation rate stabilises at 80-85%. Under high-speed crushing, the LiFePO₄ dissociation rate reaches 85% at 32,000-r/min crushing and a maximum shearing velocity of the blade edge v ≈ 500 m/s. This approach can effectively recycle electrode materials, gain valuable resources and can be used to recycle and utilise spent LIBs, thus addressing two grave issues - environmental pollution and resource wastage to achieve the sustainable development of LIBs and electric vehicle industry.

A new model of trajectory in eddy current separation for recovering spent lithium iron phosphate batteries

Eddy current separation (ECS) is an environment-friendly technology for separating nonferrous metallic particles whose size was from 2 mm to 10 mm. No wastes are generated in ECS. ECS quality of nonferrous metals from solid wastes is rather low in the production practice of spent lithium iron phosphate (LFP) batteries recovering. Repeating separation even manual sorting is required in the production. The traditional method of falling point prediction based on eddy current mechanics uses equivalent acceleration to replace separation motion curves. These curves have low precision and are unsuitable for predicting the motion trajectory of small particle size of sorted materials. In this work, eddy current separation of positive and negative plates in a crushed product of spent lithium iron phosphate battery is used as an example to establish the force and kinematics models of different materials in the eddy current separation. An iterative method, rather than average speed method, is used to improve the accuracy of the model. Displacement interval replaces disengagement angle as a separating index to improve the model's intuitiveness and practical guidance. In the range of 2-20 mm, test results are consistent with simulation results. The copper and aluminium foils at a magnetic roller speed of 800r/min can be separated to a maximum particle size ratio of 1.72, and the maximum particle size ratio of copper and positive electrode sheets can be large. This paper provided an environmental-friendly and effective technology for separating nonferrous metals from crushed spent LFP batteries.

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.

Distinct recovery of copper and aluminum from waste electric wires using a roll-type electrostatic separator

Electrostatic separators are commonly employed for the sorting of insulating and conducting fractions of granular mixtures. However, separation of the various metals that compose the conductive fraction still represents a major challenge for the recycling industry. The aim of this paper is to identify the conditions in which a roll-type electrostatic separator could be used for distinctly recover the copper and aluminum from waste electric wires. A numerical model of particle trajectories was employed to predefine these conditions and guide the experimental study. The electrostatic separation experiments were carried out using a reverse-S-type-plate high-voltage electrode. The visualization of particle trajectories using a high-speed camera paved the way to an original design. Thus, a metallic trap was attached to the high-voltage electrode, to facilitate the collection of the aluminum flake-like particles from a mixture that also contains copper strands. With a plastic trap replacing the metallic one, to avoid electric field modification, 68.6% of the copper was recovered with a purity attaining 99%.

Selective recovery of silver from waste low-temperature co-fired ceramic and valorization through silver nanoparticle synthesis

Considering the value of silver metal and silver nanoparticles, the waste generated during manufacturing of low temperature co-fired ceramic (LTCC) were recycled through the simple yet cost effective process by chemical-metallurgy. Followed by leaching optimization, silver was selectively recovered through precipitation. The precipitated silver chloride was valorized though silver nanoparticle synthesis by a simple one-pot greener synthesis route. Through leaching-precipitation optimization, quantitative selective recovery of silver chloride was achieved, followed by homogeneous pure silver nanoparticle about 100nm size were synthesized. The reported recycling process is a simple process, versatile, easy to implement, requires minimum facilities and no specialty chemicals, through which semiconductor manufacturing industry can treat the waste generated during manufacturing of LTCC and reutilize the valorized silver nanoparticles in manufacturing in a close loop process. Our reported process can address issues like; (i) waste disposal, as well as value-added silver recovery, (ii) brings back the material to production stream and address the circular economy, and (iii) can be part of lower the futuristic carbon economy and cradle-to-cradle technology management, simultaneously.