Studies on bromination and evaporation of zinc oxide during thermal treatment with TBBPA

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.

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.

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.

Recycling of zincite (ZnO) via uptake of hydrogen halides

We investigate chemical interplay between HCl/HBr and zincite surfaces as a representative model for structures of zinc oxides in EAFD.

Recovery of metals and nonmetals from electronic waste by physical and chemical recycling processes

This paper reviews the existing and state of art knowledge for electronic waste (e-waste) recycling. Electrical and/or electronic devices which are unwanted, broken or discarded by their original users are known as e-waste. The main purpose of this article is to provide a comprehensive review of e-waste problem, strategies of e-waste management and various physical, chemical and metallurgical e-waste recycling processes, their advantages and disadvantages towards achieving a cleaner process of waste utilization, with special attention towards extraction of both metallic values and nonmetallic substances. The hazards arise from the presence of heavy metals Hg, Cd, Pb, etc., brominated flame retardants (BFRs) and other potentially harmful substances in e-waste. Due to the presence of these substances, e-waste is generally considered as hazardous waste and, if improperly managed, may pose significant human and environmental health risks. This review describes the potential hazards and economic opportunities of e-waste. Firstly, an overview of e-waste/printed circuit board (PCB) components is given. Current status and future perspectives of e-waste/PCB recycling are described. E-waste characterization, dismantling methods, liberation and classification processes are also covered. Manual selective dismantling after desoldering and metal-nonmetal liberation at -150μm with two step crushing are seen to be the best techniques. After size reduction, mainly physical separation processes employing gravity, electrostatic, magnetic separators, froth floatation, etc. have been critically reviewed here for separation of metals and nonmetals, along with useful utilizations of the nonmetallic materials. The recovery of metals from e-waste material after physical separation through pyrometallurgical, hydrometallurgical or biohydrometallurgical routes is also discussed along with purification and refining. Suitable PCB recycling flowsheets for industrial applications are also given. It seems that hydrometallurgical route will be a key player in the base and precious metals recoveries from e-waste. E-waste recycling will be a very important sector in the near future from economic and environmental perspectives. Recycling technology aims to take today's waste and turn it into conflict-free, sustainable polymetallic secondary resources (i.e. Urban Mining) for tomorrow. Recycling technology must ensure that e-waste is processed in an environmentally friendly manner, with high efficiency and lowered carbon footprint, at a fraction of the costs involved with setting multibillion dollar smelting facilities. Taking into consideration our depleting natural resources, this Urban Mining approach offers quite a few benefits. This results in increased energy efficiency and lowers demand for mining of new raw materials.

Lab-scale thermal analysis of electronic waste plastics

In this work, we experimentally revealed the thermochemical decomposition pathway of Decabromodiphenyl ethane (DBDPE) and tetrabromobisphenol A (TBBPA) containing electronic waste plastics using an online thermogravimetric-fourier transform infrared-mass spectroscopy (TG-FTIR-MS) system, a high resolution gas chromatography/high resolution mass (HRGC-MS) spectroscopy, and a fixed-bed reactor. We found the distribution and species of produced bromides can be easily controlled by adjusting pyrolytic temperature, which is particularly crucial to their recycle. From the analysis of the liquid and solid phase obtained from the fixed-bed reactor, we proposed that the Br radicals formed during the pyrolysis process may be captured by organic species derived from the depolymerization of plastics to form brominated compounds or by the inorganic species in the plastics, and that these species remained in the char residue after pyrolysis. Our work for the first time demonstrates intramolecular oxygen atoms play a pivotal role in the formation of PBDD/Fs that pyrolysis of oxygen-free BFRs is PBDD/Fs-free, whereas pyrolysis of oxygen-containing BFRs is PBDD/Fs-reduced.

Brominated flame retardants and the formation of dioxins and furans in fires and combustion

The widespread use and increasing inventory of brominated flame retardants (BFRs) have caused considerable concern, as a result of BFRs emissions to the environment and of the formation of both polybrominated dibenzo-p-dioxins and dibenzofurans (PBDD/Fs) and mixed polybromochloro-dibenzo-p-dioxins and dibenzofurans (PBCDD/Fs or PXDD/Fs). Structural similarities between PBDD/Fs and polychlorinated dibenzo-p-dioxins and dibenzofurans (PCDD/Fs) suggest the existence of comparable formation pathways of both PBDD/Fs and PCDD/Fs, yet BFRs also act as specific precursors to form additional PBDD/Fs. Moreover, elementary bromine (Br2) seems to facilitate chlorination by bromination of organics, followed by Br/Cl-exchange based on displacement through the more reactive halogen. Overall, PBDD/Fs form through three possible pathways: precursor formation, de novo formation, and dispersion of parts containing BFRs as impurities and surviving a fire or other events. The present review summarises the formation mechanisms of both brominated (PBDD/Fs) and mixed dioxins (PXDD/Fs with X=Br or Cl) from BFRs, recaps available emissions data of PBDD/Fs and mixed PXDD/Fs from controlled waste incineration, uncontrolled combustion sources and accidental fires, and identifies and analyses the effects of several local factors of influence, affecting the formation of PBDD/Fs and mixed PXDD/Fs during BFRs combustion.

Study on simultaneous recycling of EAF dust and plastic waste containing TBBPA

In the present work we investigated the fates of zinc, lead, and iron present in electric arc furnace dust during thermal treatment of the dust with tetrabromobisphenol A (TBBPA) and tetrabromobisphenol A diglycidyl ether (TBBPADGE). Mixtures of these materials were compressed into pellets and heated in a laboratory-scale furnace at 550 °C for 80 min, under oxidizing and inert conditions. The solid, condensed, and gaseous-phase products were characterized using an array of analytical methods: scanning electron microscopy, X-ray diffraction, electron probe microscopy, inductively coupled plasma, ion chromatography, and gas chromatography. The results indicated that heating the mixtures under specific conditions enabled high separation of zinc and lead from iron-rich residues, by a bromination-evaporation process. In the case of TBBPADGE, a maximum of 85% of zinc and 81% of lead were effectively separated under the above conditions. The process is based on the reaction between the highly reactive HBr gas evolved during thermal degradation of the flame-retarded materials with zinc (ZnO and ZnFe2O4) and lead in the dust, followed by complete evaporation of the formed metallic bromides from the solid residue.

Fate of lead oxide during thermal treatment with tetrabromobisphenol A

In this paper, the bromination reaction between lead oxide and hydrogen bromide originating from the thermal decomposition of tetrabromobisphenol A (TBBPA), under inert and oxidizing atmospheres, was investigated, using a laboratory-scale furnace. The results obtained under inert conditions indicated that bromination of PbO proceeded simultaneously with debromination of TBBPA, with an average effectiveness of 69% (max. 80%). Volatilization of the formed PbBr2 began at 315°C, intensified at 750°C, and reached 98% at 850°C. The formed organic char served as a source of carbon for reduction of the unreacted lead oxide to metallic lead in the range 315-750°C. Additional experiments conducted at selected temperatures under slightly oxidizing (5 vol% O2) and quasi-atmospheric (20 vol% O2) conditions showed no significant effects on bromination-evaporation of lead in the studied mixture. However, in isothermal treatment under quasi-atmospheric oxygen levels, complete vaporization of the formed lead bromide was obtained at a temperature of only 650°C.

Distribution of copper, silver and gold during thermal treatment with brominated flame retardants

The growing consumption of electric and electronic equipment results in creating an increasing amount of electronic waste. The most economically and environmentally advantageous methods for the treatment and recycling of waste electric and electronic equipment (WEEE) are the thermal techniques such as direct combustion, co-combustion with plastic wastes, pyrolysis and gasification. Nowadays, this kind of waste is mainly thermally treated in incinerators (e.g. rotary kilns) to decompose the plastics present, and to concentrate metals in bottom ash. The concentrated metals (e.g. copper, precious metals) can be supplied as a secondary raw material to metal smelters, while the pyrolysis of plastics allows the recovery of fuel gases, volatilising agents and, eventually, energy. Indeed, WEEE, such as a printed circuit boards (PCBs) usually contains brominated flame retardants (BFRs). From these materials, hydrobromic acid (HBr) is formed as a product of their thermal decomposition. In the present work, the bromination was studied of copper, silver and gold by HBr, originating from BFRs, such as Tetrabromobisphenol A (TBBPA) and Tetrabromobisphenol A-Tetrabromobisophenol A diglycidyl ether (TTDE) polymer; possible volatilization of the bromides formed was monitored using a thermo-gravimetric analyzer (TGA) and a laboratory-scale furnace for treating samples of metals and BFRs under an inert atmosphere and at a wide range of temperatures. The results obtained indicate that up to about 50% of copper and silver can evolve from sample residues in the form of volatile CuBr and AgBr above 600 and 1000°C, respectively. The reactions occur in the molten resin phase simultaneously with the decomposition of the brominated resin. Gold is resistant to HBr and remains unchanged in the residue.

Removal of tetrabromobisphenol A by conventional activated sludge, submerged membrane and membrane aerated biofilm reactors

The goal of this study was to compare removal efficiencies of tetrabromobisphenol A (TBBPA) using typical wastewater treatment technologies, and to identify the most significant mechanisms of removal. Two types of municipal wastewater reactors were studied: a full-scale conventional activated sludge (CAS) reactor with tertiary treatment; and three pilot-scale membrane bioreactors (MBRs) having different sludge retention times (SRTs). All four reactors were fed the same influent. A third reactor type, a membrane aerated biofilm reactor (MABR) was fed tap water, ammonia, and TBBPA. TBBPA in municipal influent ranged from 1 to 41 ng L(-1) (n=10). The CAS effluent had an average TBBPA concentration of 0.7 ± 1.3 ng L(-1) (n=3). Effluent concentrations from the MBRs were an average of 6 ± 6 ng L(-1) TBBPA (n=26). Significant TBBPA removal was observed in the MABR throughout the 5 week of study (p≥0.05). Removal of TBBPA from wastewater treatment was found to be due to a combination of adsorption and biological degradation. Based on experimental results, nitrification is likely a key process therein. No significant relationship between removal of TBBPA and SRT was identified (p≥0.05).

Vaporization of zinc during thermal treatment of ZnO with tetrabromobisphenol A (TBBPA)

In the present work we investigate the vaporization of zinc or its compounds during thermal treatment of ZnO with tetrabromobisphenol A. Samples of 2g of ZnO:TBBPA (3.34:1) were isothermally heated in a laboratory-scale furnace at temperatures from 490 °C to 950 °C, and the solid, condensed and gaseous products formed were analyzed by X-ray diffraction analysis, electron probe microanalysis, inductively coupled plasma analysis, ion chromatography, and gas chromatography coupled with mass spectrometry. The results obtained indicate that the vaporization of ZnBr(2) formed strongly depends on heating time and temperature, yet is restrained by char, if formed with sufficient yield (above 15 wt%). Starting from 850 °C, this char commences carbothermic reduction of any remaining ZnO, which from then begins to evaporate as zinc metal vapor. Volatilization of zinc is completed at 950 °C. The presence of 5 vol.% of oxygen has no significant effect on the vaporization of formed ZnBr(2), the carbothermic reduction or the volatilization of metallic zinc. Strongly oxidizing conditions (20 vol.% of oxygen), however, boost the oxidation of char and thus the vaporization of ZnBr(2), but prevent carbothermic reduction of any un-reacted ZnO by depleting this char.

Characteristics of exhaust gas, liquid products, and residues of printed circuit boards using the pyrolysis process

INTRODUCTION

The pyrolytic method was employed to recycle metals and brominated compounds blended into printed circuit boards (PCBs).

METHODS

PCBs were crushed into pieces 4.0-4.8 mm in size, and the crushed pieces were pyrolyzed at temperatures ranging from 200 to 500 degrees C. The compositions of pyrolytic residues, liquid products, and exhaust were analyzed by inductively coupled plasma atomic emission spectrometer, inductively coupled plasma mass spectrometry, and gas chromatography-mass spectrometry. Pyrolytic exhaust was collected by an impinger system in an ice bath cooler to analyze the composition fraction of the liquid product, and uncondensable exhaust was collected for gas constituent analysis.

RESULTS

Phenol, methyl-phenol, and bromo-phenol were attributed mainly to the liquid product. Metal content was low in the liquid product. In addition, CO, CO(2), CH(4), and H(2) were the major components of pyrolytic exhaust.

CONCLUSIONS

Brominated and chlorinated compounds-i.e., dichloromethane, trans-1,2 dichloroethylene, cis-1,2 dichloroethylene, 1,1,1-trichloroethane, tetrachloromethane, bromophenol, and bromoform-could be high, up to the several parts per million (ppm) level. Low molecular weight volatile organic compounds (VOCs)-i.e., methanol, acetone, ethyl acetate, acrylonitrile, 1-butene, propene, propane, and n-butane-contributed a large fraction of VOCs. The concentrations of toluene, benzene, xylene, ethylbenzene, and styrene were in the ppm range.

Influence of temperature and heating time on bromination of zinc oxide during thermal treatment with tetrabromobisphenol A

Our prior research indicates that hydrogen bromide (HBr) evolved during thermal decomposition of tetrabromobisphenol A (TBBPA) can be utilized as a reagent for selective bromination and evaporation of zinc oxide. The present work investigated dependency of the bromination reaction on time at selected temperatures using a laboratory-scale furnace. The formed solid, condensed, and gaseous products were analyzed by X-ray diffraction analysis, electron probe microanalysis, inductively coupled plasma analysis, ion chromatography, and gas chromatography coupled with mass spectrometry. Results indicate that the bromination rate is strongly dependent on heating time. This dependency is a direct consequence of progress in the decomposition of TBBPA, which provides inorganic bromine suitable for the reaction. The bromination rate increases with time until the bromine source is depleted. The process is shorter at higher applied temperatures and appears instantaneous at 310 degrees C and above. However, the maximum bromination yield is independent of the applied conditions and ranges from 64 to 70%. Additionally, the influence of oxidizing conditions on the bromination reaction and the effect of ZnO on decomposition of TBBPA were investigated in this study.