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

Potential of metallurgical iron-containing solid waste-based catalysts as activator of persulfate for organic pollutants degradation

The production of solid wastes in the metallurgical industry has significant implications for land resources and environmental pollution. To address this issue, it is crucial to explore the potential of recycling these solid wastes to reduce land occupation while protecting the environment and promoting resource utilization. Steel slag, red mud, copper slag and steel picking waste liquor are examples of solid wastes generated during the metallurgical process that possess high iron content and Fe species, making them excellent catalysts for persulfate-based advanced oxidation processes (PS-AOPs). This review elucidates the catalytic mechanisms and pathways of Fe2+ and Fe0 in the activation PS. Additionally, it underscores the potential of metallurgical iron-containing solid waste (MISW) as a catalyst for PS activation, offering a viable strategy for its high-value utilization. Lastly, the article provides an outlook towards future challenges and prospects for MISW in PS activation for the degradation of organic pollutants.

Biolixiviation of Metals from Computer Printed Circuit Boards by Acidithiobacillus ferrooxidans and Bioremoval of Metals by Mixed Culture Subjected to a Magnetic Field

Crushed and ground printed circuit board (PCB) samples were characterized to evaluate copper, lead, and aluminum using X-ray fluorescence spectroscopy (XRF) and the morphology was done by scanning electron microscopy (SEM). The XRF characterizations showed 0.12% lead, 3.72% copper, and 12.73% aluminum in the PCBs. The metal solubilization experiments using Acidithiobacillus ferrooxidans indicated higher values of total metal solubilization when the initial pH of the inoculum was adjusted. However, these experiments did not show higher metal solubilization by bioleaching. The sequential bioremoval experiments using mixed culture after bioleaching assays with A. ferrooxidans with initial adjustment of inoculum pH and without applying a magnetic field removed 100% of Al, 27.34% of Cu, and 96.43% of Pb from the lixiviate medium; with magnetic field application, 100% of Al, 83.82% of Cu, and 98.27% of Pb were removed. A similar bioleaching experiment without inoculum pH adjustment and without field application achieved 99.74% removal for Cu and 91.92% for Pb. When the magnetic field was applied, 100% of Cu and 95.76% of Pb were removed. Bioreactors with a magnetic field do not show significantly better removal of any of the metals analyzed.

Selective Gold and Palladium Adsorption from Standard Aqueous Solutions

The intensive exploitation of resources on a global level has led to a progressive depletion of mineral reserves, which were proved to be insufficient to meet the high demand for high-technological devices. On the other hand, the continuous production of Waste from Electrical and Electronic Equipment (WEEE) is causing serious environmental problems, due to the complex composition of WEEE, which makes the recycling and reuse particularly challenging. The average metal content of WEEE is estimated to be around 30% and varies depending on the manufacturing period and brand of production. It contains base metals and precious metals, such as gold and palladium. The remaining 70% of WEEEs is composed of plastics, resins, and glassy materials. The recovery of metals from WEEEs is characterized by two main processes well represented by the literature: Pyrometallurgy and hydrometallurgy. Both of them require the pre-treatment of WEEEs, such as dismantling and magnetic separation of plastics. In this work, the selective adsorption of precious metals has been attempted, using copper, gold, and palladium aqueous solutions and mixtures of them. A screening on different adsorbent materials such as granular activated carbons and polymers, either as pellets or foams, has been performed. Among these, PolyEther Block Amide (PEBA) was elected as the most performing adsorbent in terms of gold selectivity over copper. Spent PEBA has been then characterized using scanning electron microscope, coupled with energy dispersive spectroscopy, demonstrating the predominant presence of gold in most analyzed sites, either in the pellet or foam form.

Advanced utilization of copper in waste printed circuit boards: Synthesis of nano-copper assisted by physical enrichment

The copper in the waste printed circuit boards (WPCBs) is cleanly recycled by physical methods and presented in the form of nano copper particles by hydrometallurgical, which provides environmental approach to the advanced utilization of metal copper. Copper in WPCBs was first pre-concentrated by gradient enrichment process including gravity separation, mechanical grinding and flotation. The leaching method was then used to dissolve copper from the flotation concentrate in ammoniacal/ammonium salt solutions. Subsequently, reduction treatment was conducted to synthesize nano-copper from leaching solution. The enrichment results of the clean physical separation process show that the grade of copper increased from 16.22% to -38.05% by gravity separation, and the grade of copper further increased to 72.62 % by flotation after dissociation, which avoids overgrinding of low value components. Copper nanoparticles can be prepared effectively, and the recovery of copper in the leaching process reaches 99 %. The particle size of copper nanoparticles obtained by ascorbic acid reduction is tens of nanometers, and the surface of copper nanoparticles is smooth and nearly spherical. The present study proposes an environmentally friendly process of preparing nano-copper from the copper in WPCBs.

Nanoflakes of chloride zinc–iron–aluminum-based layered double hydroxides obtained from industrial waste: a green approach to mass-scale production

A greener technology aiming at a smarter industrial waste treatment is proposed to produce chloride iron–zinc–aluminum layered double hydroxides (LDHs). Waste Pickling Acid (WPA) and sodium aluminate (NaAlO₂) from secondary sources were meticulously mixed under mild experimental conditions using a sodium hydroxide solution as a pH-regulator. A set of characterization techniques (XRD, SEM, TGA, FTIR, AAS and adsorption–desorption of N₂) indicated the formation of highly-dispersed nanoflake crystallites with textural characteristics and thermal stability similar to syntheses with high-quality chemicals. An interesting discussion on chemical composition and M²⁺/M³⁺ molar ratio is presented. Although the co-precipitation synthesis was conducted without control of environmental CO₂, complete intercalation of the chloride anion was achieved, making these particles more favorable for further anion exchange applications. The experimental variables temperature of reaction and WPA/NaAlO₂ volume ratio showed the strongest influence on the LDHs crystallinity and porosity. LDHs architected with iron and zinc have the potential to be applied in systems for removing sulfur gases for cleaner energy production, e.g. in the refining process of biogas to produce biomethane.

A greener technology aiming at a smarter industrial waste treatment is proposed to produce chloride iron–zinc–aluminum layered double hydroxides (LDHs).

Effect of Graphite on Copper Bioleaching from Waste Printed Circuit Boards

The efficient extraction of copper as a valuable metal from waste printed circuit boards (WPCBs) is currently attracting growing interest. Here, we systematically investigated the impact of bacteria on the efficiency of copper leaching from WPCBs, and evaluated the effect of graphite on bioleaching performance. The HQ0211 bacteria culture containing Acidithiobacillus ferrooxidans, Ferroplasma acidiphilum, and Leptospirillum ferriphilum enhanced Cu-leaching performance in either ferric sulfate and sulfuric acid leaching, so a final leaching of up to 76.2% was recorded after 5 days. With the addition of graphite, the percentage of copper leaching could be increased to 80.5%. Single-factor experiments confirmed the compatibility of graphite with the HQ0211 culture, and identified the optimal pulp density of WPCBs, the initial pH, and the graphite content to be 2% (w/v), 1.6, and 2.5 g/L, respectively.

Effect of thermal shock process on the microstructure and peel resistance of single-sided copper clad laminates used in waste printed circuit boards

Efficient pre-processing is essential to the mechanical recovery of waste printed circuit boards (WPCBs). In this work, a thermal shock pretreatment was utilized to damage the interface between metals and nonmetals of single-sided copper clad laminates (SSCCLs), which are usually employed as the base material of printed circuit boards (PCBs). The effects of three thermal shock treatment parameters-i.e., peak temperature, holding time, and thermal shock cycle times-on the adhesion strength of SSCCLs were evaluated by orthogonal experiments. Microstructures and peel resistance of SSCCLs before and after thermal shock were characterized by scanning electron microscopy (SEM) and 90° peel test, respectively. Our results showed that the impact of three major factors that influence liberation efficiency was in the sequence of peak temperature > shock cycle times > holding time. Furthermore, the optimal thermal shock level could be achieved when the peak temperature was 300°C with the soaking time of 30 min and three cycle times. In the meantime, the corresponding peel strength of the SSCCLs (0.065 N/mm) was sharply decreased by 94% in comparison with those without thermal shock treatment. The manual dismantling experimental data verified the good feasibility of the optimal thermal shock process, suggesting that the copper foil could be readily dismantled from the substrate by hand after pretreatment, with a successful separation rate of 100% and a peeling efficiency of ~ 30 seconds per piece. Therefore, the optimal thermal shock process could notably improve liberation of metals and nonmetals, which would be helpful for efficient recycling of WPCBs.Implications: The interface between copper foil and laminate dielectric in a PCB can be weakened significantly via efficient thermal shock method. Thus, a good liberation could be achieved after thermal shock. In this work, a manual peeling of copper foil from the SSCCL substrates was achieved efficiently after optimal thermal shock pretreatment, confirming the feasibility of a shorter process of metal recovery from scrap SSCCLs without pulverization. The results will be useful for the pretreatment of recovery of the WPCBs.

Recovery of heavy metals from waste printed circuit boards: statistical optimization of leaching and residue characterization

Despite attempts to enhance the recycling of waste printed circuit boards (WPCBs), the simultaneous recovery of major metals of WPCBs using an efficient approach is still a great challenge. This study mainly concerned with applying an effective statistical tool to optimize the recovery of metal content (i.e., Cu, Fe, Zn, Pb, Ni, Sn, and Al) embedded in WPCBs using a leaching agent without any additive or oxidative agent. Another target was to optimize a multi-response recovery process by minimizing time, energy, and acid consumption during the leaching. Effective parameters and their levels, including leaching time (20-60 min), temperature (25-45 °C), solid to liquid (S/L) ratio (1/8-1/20 g/ml), and acid molarity (1-2.7 M), were optimized. A well-established statistical approach (i.e., response surface methodology (RSM)) was applied to precisely quantify and interpret the effects. General optimum conditions for nine responses were introduced with the desirability of ≈ 85%. Finally, the solid residue of leaching was characterized and results showed the morphology, structure, and composition of the residue content (i.e., polymers and ceramics) remained the same after the leaching, indicating the neutral behavior of the leaching process on these two materials. Also, thermal behavior and phase analysis of the original WPCBs and leaching residue were compared and analyzed. Graphical abstract.