Removal of Bromine from the non-metallic fraction in printed circuit board via its Co-pyrolysis with alumina

Debromination of novel brominated flame retardants using Zn-based additives: A viable thermochemical approach in the mitigation of toxic effects during e-waste recycling

Brominated flame retardants (BFRs) are bromine-bearing additives added to the polymeric fraction in various applications to impede fire ignition. The Stockholm Convention and various other legislations abolished legacy BFRs usage and hence, the so-called novel BFRs (NBFRs) were introduced into the market. Recent studies spotlighted their existence in household dust, aquifers and aquatic/aerial species. Co-pyrolysis of BFRs with metal oxides has emerged as a potent chemical recycling approach that produces a bromine-free stream of hydrocarbon. Herein, we investigate the debromination of two prominent two NBFRs; namely tetrabromobisphenol A 2,3-dibromopropyl ether (TD) and tetrabromobisphenol A diallyl ether (TAE) through their co-pyrolysis with zinc oxide (ZnO) and franklinite (ZnFe2O4). Most of the zinc content in electrical arc furnace dust (EAFD) exists in the form of these two metal oxides. Conversion of these metal oxides into their respective bromides could also assist in the selective extraction of the valuable zinc content in EAFD. The debromination potential of both oxides was unveiled via a multitude of characterization studies to analyze products (char, gas and condensates). The thermogravimetric analysis suggested a pyrolytic run up to 500 °C and the TAE treatment with ZnO produced only a trivial amount of brominated compounds (relative area, 0.83%). Phenol was the sole common compound in condensable products; potentially formed by the β-scission debromination reaction from the parental molecular skeleton. Inorganic compounds and methane were the major constituents in the gaseous products. The pyrochar analyses confirmed the presence of metal bromides retained in the residue, averting the bromine release into the atmosphere. The ion chromatography analysis portrayed <8% of HBr gas release into the atmosphere upon pyrolysis with ZnO. The ZnO dominance herein envisaged further probes into other spinel ferrites in combating brominated polymers.

A novel subcritical water synergistic co-treatment of brominated epoxy resin and copper-based spent catalysts: debromination, phenol production, and copper recovery

In this study, a high-efficiency co-treatment strategy for brominated epoxy resin (BER) and copper-based spent catalyst (CBSC) was developed by using subcritical water (SubCW) process. Multivalent species of copper released from CBSC could accelerate the electron transfer of the SubCW system and efficiently catalyze radical reactions to promote the debromination and decomposition of BER, and had an effect on the capture and binding of bromine species. Meanwhile, the formation of HBr by the BER debromination resulted in a decrease in the system pH and markedly enhanced the leaching/recovery of Cu from CBSC. The optimal conditions of the SubCW co-treatment process were as follows: reaction temperature of 350 °C, solid-to-liquid ratio of 1:30 g/mL, BER-to-CBSC mass ratio of 10:1 g/g, and reaction time of 60 min. Under the optimal conditions, 97.12 % of the Br could be removed from BER by the SubCW co-treatment process and a high-purity phenol (64.09 %) could be obtained in the oil phase product, and 86.44 % of Cu in the CBSC could be leached and recovered. The introduction of CBSC significantly changed the decomposition path of BER. Compared to the SubCW process without CBSC, bromine-free oils products could be obtained by the co-treatment process of BER and CBSC at low-temperature. This study provided a novel understanding of resource conversion mechanism of BER and CBSC in subcritical water medium via the synergistic effect between the two different waste streams to improve treatment efficiency and synchronously recover high-value products.

Quantum chemical study on the catalytic debromination mechanism of brominated epoxy resins

The study employed Density Functional Theory (DFT) to investigate the catalytic debromination mechanism of brominated epoxy resins (BERs) by iron (Fe) and copper (Cu) catalysts. By introducing electric field (EF), intramolecular electron transfer and polarization effects on BERs debromination were explored and experimentally validated. Results indicated that the bond dissociation energy (BDE) of the C-Br bond was 312.27 kJ/mol without catalysis, while with Fe, Cu, and EF, it was 114.47 kJ/mol, 94.85 kJ/mol, and 292.59 kJ/mol, respectively, enhancing reactivity. EF parallel to the C-Br bond and oriented toward the C atom, altered electrostatic potential and dipole moment around C-Br bond, leading to 68.60% and 50.19% increment in electronic contribution difference and molecule polarity, respectively, thereby reducing the C-Br BDE. Fe and Cu facilitated electron transfers with BERs, inducing reactions between their negative electrostatic potentials and Br's positive potential, changing electron sharing, resulting in 19.87% and 12.11% increase in polarity, respectively, and further BDE reduction. Structural modifications by the EF and catalysts also intensified van der Waals forces with bromine atoms and decreased spatial hindrance, collectively making C-Br bond breakage easier. Experiments revealed the EF enhanced BERs' debromination efficiency but hindered Fe/Cu's catalysis at lower temperatures.

Recent Advancements in Pyrolysis of Halogen-Containing Plastics for Resource Recovery and Halogen Upcycling: A State-of-the-Art Review

Plastic waste has emerged as a serious issue due to its impact on environmental degradation and resource scarcity. Plastic recycling, especially of halogen-containing plastics, presents challenges due to potential secondary pollution and lower-value implementations. Chemical recycling via pyrolysis is the most versatile and robust approach for combating plastic waste. In this Review, we present recent advancements in halogen-plastic pyrolysis for resource utilization and the potential pathways from "reducing to recycling to upcycling" halogens. We emphasize the advanced management of halogen-plastics through copyrolysis with solid wastes (waste polymers, biomass, coal, etc.), which is an efficient method for dealing with mixed wastes to obtain high-value products while reducing undesirable substances. Innovations in catalyst design and reaction configurations for catalytic pyrolysis are comprehensively evaluated. In particular, a tandem catalysis system is a promising route for halogen removal and selective conversion of targeted products. Furthermore, we propose novel insights regarding the utilization and upcycling of halogens from halogen-plastics. This includes the preparation of halogen-based sorbents for elemental mercury removal, the halogenation-vaporization process for metal recovery, and the development of halogen-doped functional materials for new materials and energy applications. The reutilization of halogens facilitates the upcycling of halogen-plastics, but many efforts are needed for mutually beneficial outcomes. Overall, future investigations in the development of copyrolysis and catalyst-driven technologies for upcycling halogen-plastics are highlighted.

Prediction of Thermogravimetric Data in the Thermal Recycling of e-waste Using Machine Learning Techniques: A Data-driven Approach

The release of bromine-free hydrocarbons and gases is a major challenge faced in the thermal recycling of e-waste due to the corrosive effects of produced HBr. Metal oxides such as Fe2O3 (hematite) are excellent debrominating agents, and they are copyrolyzed along with tetrabromophenol (TBP), a lesser used brominated flame retardant that is a constituent of printed circuit boards in electronic equipment. The pyrolytic (N2) and oxidative (O2) decomposition of TBP with Fe2O3 has been previously investigated with thermogravimetric analysis (TGA) at four different heating rates of 5, 10, 15, and 20 °C/min, and the mass loss data between room temperature and 800 °C were reported. The objective of our paper is to study the effectiveness of machine learning (ML) techniques to reproduce these TGA data so that the use of the instrument can be eliminated to enhance the potential of online monitoring of copyrolysis in e-waste treatment. This will reduce experimental and human errors as well as improve process time significantly. TGA data are both nonlinear and multidimensional, and hence, nonlinear regression techniques such as random forest (RF) and gradient boosting regression (GBR) showed the highest prediction accuracies of 0.999 and lowest prediction errors among all the ML models employed in this work. The large data sets allowed us to explore three different scenarios of model training and validation, where the number of training samples were varied from 10,000 to 40,000 for both TBP and TBP + hematite samples under N2 (pyrolysis) and O2 (combustion) environments. The novelty of our study is that ML techniques have not been employed for the copyrolysis of these compounds, while the significance is the excellent potential of enhanced online monitoring of e-waste treatment and extension to other characterization techniques such as spectroscopy and chromatography. Lastly, e-waste recycling could greatly benefit from ML applications since it has the potential to reduce total and operational costs and improve overall process time and efficiency, thereby encouraging more treatment plants to adopt these techniques, resulting in reducing the increasing environmental footprint of e-waste.

Co-pyrolysis of paper-laminated phenolic printed circuit boards and calcium-based additives in fixed and fluidized bed reactors

This study compares the impact of the calcium-based additives and the pyrolyzer on the recovery and the halide content of the oil produced from the pyrolysis of paper-laminated phenolic resin printed circuit boards (FR2-PCB). The preliminary experiments showed that the maximum liquid recovery (40.6%) was achieved in a fluidized bed pyrolyzer containing a 50:50 mixture of CaO and Ca(OH)2 operating at T = 620 °C and PCB-to-additive ratio (FR2/A) = 5.4 g/g for 22 min. Extra tests were then carried out under these conditions in fixed and fluidized bed pyrolyzers to separately explore the impact of CaO, Ca(OH)2, and CaO + Ca(OH)2 on the liquid recovery (LR) and the halogen content of the non-solid products. In the fluidized bed, LR in the presence of CaO, Ca(OH)2, and CaO + Ca(OH)2 was 34.5%, 41.2%, and 38.9 wt%, respectively. The fraction of phenolic compounds in the pyrolysis oil ranged from 86% to 93%, about 1-3% higher than the corresponding values in the fixed bed. Using additives led to lower halide content in the pyrolysis oil of the fluidized bed than that of the fixed bed. However, the opposite trend was observed in the absence of additives. Regardless of the type of pyrolyzer, Ca(OH)2 was more successful than CaO in increasing LR, whereas CaO was more effective than Ca(OH)2 in pyrolysis oil dechlorination. Co-pyrolysis of FR2-PCB and CaO + Ca(OH)2 in a fluidized bed reactor was identified as a practical approach to enhance the recovery of pyrolysis oil comprising only 5% of the original halogen content of the feedstock.

Catalytic pyrolysis of waste printed circuit boards to organic bromine: reaction mechanism and comprehensive recovery

The production of waste printed circuit boards (WPCBs) is increasing, and its complex composition makes recycling difficult. In addition, the presence of heavy metals and brominated flame retardants makes it a hazardous waste. Therefore, its recycling is a necessary way for resource recycling and green sustainable development. The purpose of this study is to propose a green, efficient, and pollution-free recycling process as an alternative to recycle WPCBs. In this work, an alkaline metal oxide catalytic pyrolysis process was used to recover WPCBs. In the presence of alkali metal oxides (such as Ca(OH)2) and coexisting copper, Ca(OH)2 and coexisting copper are transformed into CaBr2 and Cu Br by reacting with organic bromine in WPCBs and remaining in the solid phase product. The bromine content and the proportion of inorganic bromine in the solid phase products were 87.68% and 87.56%, respectively. In addition, the content of organic bromine in the pyrolysis oil obtained by co-pyrolysis was significantly reduced. This study demonstrated the feasibility of Ca(OH)2 catalytic pyrolysis for WPCB recovery.

Combating toxic emissions from thermal recycling of polymeric fractions laden with novel brominated flame retardants (NBFRs) in e-waste: an in-situ approach using Ca(OH)2

Legacy brominated flame retardants (BFRs) in printed circuit boards are gradually being replaced by novel BFRs (NBFRs). Safe disposal and recycling of polymeric constituents in the polymeric fractions of e-waste necessitate the removal of their toxic and corrosive bromine content. This is currently acquired through thermal recycling operations involving the pyrolysis of BFRs-containing materials with metal oxides. Nonetheless, the debromination capacity toward NBFRs is yet to be established. Thus, this study aims to address these two crucial gaps in the current knowledge pertaining to the plausible formation of brominated toxicants from the thermal decomposition of NBFRs and their thermal recycling potential. Herein, we investigate the pyrolysis of a mixture of 2,4,6-tribromophenol (TBP), allyl 2,4,6-tribromophenyl ether (ATE) and Tetrabromobisphenol A-bis (2,3-dibromo propyl ether) (TBBPA-DBPE) in the presence of acrylonitrile butadiene styrene (ABS) polymers at various loads. To demonstrate a viable debromination route, pyrolysis of NBFRs-ABS mixture with Ca(OH)2 was also investigated. The latter is a potent debromination agent for legacy BFRs. Upon pyrolysis with Ca(OH)2, the bromine content in the collected oil was reduced up to 80.49% between 25-500 °C. Products of the co-pyrolysis process generally feature non-brominated aromatic and aliphatic compounds; a finding that indicates an effective thermal recycling approach. As evident by IC measurements, no HBr emission could be detected when Ca(OH)2 is added to the mixture. As XRD patterns show, Ca(OH)2 is partially converted into CaBr2. DFT calculations provide pathways for the observed surface debromination characterized by surface-assisted fission of aromatic C-Br bonds and the formation of CaBr sites. Outcomes reported herein are instrumental to designing and operating a thermal recycling facility of polymeric materials contaminated with high loads of bromine, i.e., most notably during scenarios encountered in the thermal recycling of e-waste.

Investigation of pyrolysis for the recovery of metallic values from ball grid arrays

The massive generation of electronic waste has led to a significant interest in sustainable metal recovery and recycling. Ball grid arrays, mounted on printed circuit boards, are identified as a potentially valuable source of metals (Cu, Ni, Au, Ag, Pb, and Sn). In this study, pyrolysis is found as a promising treatment for the degradation of the epoxy resin of ball grid arrays. As a consequence, the liberation of metallic values and glass fibers is attained. The thermal analysis revealed that the major degradation occurs in the temperature range of 300-650 °C, with overall activation energy estimated as ~ 243 kJ/mol. The concentration of CO gas reaches a maximum value at a comparatively lower residence time with an increase in pyrolysis temperature. The metal enrichment was significantly influenced by the variation in pyrolysis temperatures with an optimal condition chosen as 600 °C. The metallic fractions (Cu, Ni, Ag, and Au) were separated from the glass fibers by water-based density separation and enriched in the sink product by three-fold. The recovery of Cu, Ni, Ag, and Au is achieved at 97%, 88%, 95%, and 96%, respectively. The metal fraction can be either used as a feedstock for the Cu smelting process or can be subjected to selective hydrometallurgical treatment. The glass fiber fraction comprises of Si, Al, and Ca oxides with potential application in laminate fabrication. High-quality gaseous products can be reutilized as fuel for other metallurgical processes. It can be concluded that 100 g of BGA yielded Cu ~ 23.7 g, Ni ~ 0.57 g, Ag ~ 23.4 mg, and Au ~ 73 mg after pyrolysis and density separation, which is equivalent to 1.35 kg, of primary Cu ore, 0.042 kg Ni ore, 4.68 kg Ag ore, and 14.6 kg Au ore.

Mechanochemical debromination of allyl 2,4,6-tribromophenyl ether (TBP-AE): optimization of the operational conditions

Allyl 2,4,6-tribromophenyl ether (TBP-AE) is a flame retardant that is added to plastics to improve their fire resistance. This kind of additive is hazardous to both human health and the environment. As any other BFRs, TBP-AE resists photo-degradation in the environment and hence materials laden with TBP-AE are to be dibrominated to avoid environmental pollution. Mechanochemical degradation of TBP-AE is a promising approach with potential industrial applications since it does not require high temperatures nor it generates any secondary pollutants. A planetary ball milling simulation experiment was designed to study TBP-AE's mechanochemical debromination. To report products from the mechanochemical process, a variety of characterization techniques were used. The characterization methods included gas chromatography-mass spectrometry (GC-MS), X-ray powder diffraction (XRD), Fourier transform infrared spectroscopy (FT-IR), and scanning electron microscopy (SEM) with energy-dispersive X-ray analysis (EDX). The effects of various co-milling reagent types, co-milling reagent concentrations with raw material, time, and revolution speed on mechanochemical debromination efficiency have been thoroughly investigated. The Fe/Al2O3 mixture entails the highest debromination efficiency of 23%. However, when using a Fe/Al2O3 mixture, neither the reagent concentration nor the revolution speed influenced the debromination efficiency. In case of using only Al2O3, the next viable reagent, it was revealed that while increasing the revolution, speed improved debromination efficiency to a certain point, and increasing it any further left the debromination efficiency unchanged. In addition, the results showed that an equal mass ratio of TBP-AE to Al2O3 promoted degradation more than an increase in the ratio of Al2O3 to TBP-AE. The addition of ABS polymer largely inhibits the reaction between Al2O3 and TBP-AE, which hindered alumina's ability to capture organic bromine, causing a significant decrease in the debromination efficiency when model of waste printed circuit board (WPCB) is considered.

Debromination with Bromine Recovery from Pyrolysis of Waste Printed Circuit Boards Offers Economic and Environmental Benefits

Bromine is an important resource that is widely used in medical, automotive, and electronic industries. Waste electronic products containing brominated flame retardants can cause serious secondary pollution, which is why catalytic cracking, adsorption, fixation, separation, and purification have gained significant attention. However, the bromine resources have not been effectively reutilized. The application of advanced pyrolysis technology could help solve this problem via converting bromine pollution into bromine resources. Coupled debromination and bromide reutilization during pyrolysis is an important field of research in the future. This prospective paper presents new insights in terms of the reorganization of different elements and adjustment of bromine phase transition. Furthermore, we proposed some research directions for efficient and environmentally friendly debromination and reutilization of bromine: 1) precise synergistic pyrolysis should be further explored for efficient debromination, such as using persistent free radicals in biomass, polymer hydrogen supply, and metal catalysis, 2) rematching of Br elements and nonmetal elements (C/H/O) will be a promising direction for synthesizing functionalized adsorption materials, 3) oriented control of the bromide migration path should be further studied to obtain different forms of bromine resources, and 4) advanced pyrolysis equipment should be well developed.

Degradation of tetrabromobisphenol A (TBBA) with calcium hydroxide: a thermo-kinetic analysis

Thermal treatment of bromine-contaminated polymers (i.e., as in e-waste) with metal oxides is currently deployed as a mainstream strategy in recycling and resources recovery from these objects. The underlying aim is to capture the bromine content and to produce pure bromine-free hydrocarbons. Bromine originates from the added brominated flame retardants (BFRs) to the polymeric fractions in printed circuits boards, where tetrabromobisphenol A (TBBA) is the most utilized BFR. Among notable deployed metal oxides is calcium hydroxide, i.e., Ca(OH)₂ that often displays high debromination capacity. Comprehending thermo-kinetic parameters that account for the BFRs:Ca(OH)₂ interaction is instrumental to optimize the operation at an industrial scale. Herein, we report comprehensive kinetics and thermodynamics studies into the pyrolytic and oxidative decomposition of a TBBA:Ca(OH)₂ mixture at four different heating rates, 5, 10, 15, and 20 °C min^-1, carried out using a thermogravimetric analyser. Fourier Transform Infrared Spectroscopy (FTIR) and a carbon, hydrogen, nitrogen, and sulphur (CHNS) elemental analyser established the vibrations of the molecules and carbon content of the sample. From the thermogravimetric analyser (TGA) data, the kinetic and thermodynamic parameters were evaluated using iso-conversional methods (KAS, FWO, and Starink), which were further validated by the Coats-Redfern method. The computed activation energies for the pyrolytic decomposition of pure TBBA and its mixture with Ca(OH)₂ reside in the narrow ranges of 111.7-112.1 kJ mol^-1 and 62.8-63.4 kJ mol^-1, respectively (considering the various models). Obtained negative ΔS values suggest the formation of stable products. The synergic effects of the blend exhibited positive values in the low-temperature ranges (200-300 °C) due to the emission of HBr from TBBA and the solid-liquid bromination process occurring between TBBA and Ca(OH)₂. From a practical point of view, data provided herein are useful in efforts that aim to fine-tune operational conditions encountered in real recycling scenarios, i.e., in co-pyrolysis of e-waste with Ca(OH)₂ in rotary kilns.

Oxidative and pyrolytic decomposition of an evaporated stream of 2,4,6-tribromophenol over hematite: A prevailing scenario during thermal recycling of e-waste

Brominated flame retardants (BFRs) constitute a major load in the polymeric fraction of e-waste. Degradation of BFRs-laden plastics over transition metal oxides is currently deployed as a mainstream strategy in the disposal and treatment of the non-metallic segment of e-waste. However, interaction of pyrolysis's products of BFRs with transition metal oxides is well-known to facilitate the formation of notorious pollutants. Despite recent progress to comprehend the germane chemistry of this interaction, several important pertinent aspects remain to be addressed. To fill in this gap, an integrated experimental and simulation account of the pyrolytic and oxidative decomposition of a gaseous stream of 2,4,6-tribromophenol (TBP) over hematite (Fe2O3) has been reported herein. TBP is utilized as a model compounds of BFRs as their most common formulations include brominated phenolic rings. Overall, hematite entails a rather low cracking capacity under pyrolytic conditions. Analysis of condensate products indicates that oxidative degradation of a gaseous stream of TBP results mainly in the formation of brominated alkanes such as bromoethane and bromo-pentane. Likewise, Ion chromatography (IC) measurements disclosed a noticeable reduction in the concentrations of escaped HBr. Transformation of iron oxides into iron bromides (possibly in the form of FeBr2) during pyrolysis and combustion operations is evident through XRD measurements. Density functional theory (DFT) calculations map out important reactions pathways that operate in the initial degradation of the TBP molecule. From a broader perspective, outlined results shall be instrumental to precisely assess the effectiveness of using iron oxides in thermal catalytic recycling of e-waste and the likely emission of brominated toxicants.