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

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.

NOx removal and copper recovery from the leaching process for waste printed circuit boards: performance evaluation and potential environmental impact assessment

Resource recovery is crucial for small- and medium-sized enterprises to attain a circular economy. The economic benefits of recovering precious metals from electronic waste, such as waste printed circuit boards (WPCBs), are hindered by secondary pollutant emissions from pretreatment processes. This study aims to recover copper from the WPCB acid leaching process and reduce NOx emissions through the use of a high gravity rotating packed bed (RPB). The results indicate that the copper recovery ratio increases to 99.75% through the displacement reaction between iron powder and copper nitrate. The kinetic analysis of copper dissolution was employed to simulate the NOx emissions during acid leaching, with an R-squared value of 0.872. Three oxidants, including H2O2(aq), ClO2(aq), and O3(g), with pH adjusted to different NaOH concentrations, were used to remove NOx. The greatest NOx removal rate was achieved using a 0.06 M NaOH solution, with a removal rate of 91.2% for ozone oxidation at a 152-fold gravity level and a gas-to-liquid (G/L) ratio of 0.83. The gas-side mass transfer coefficients (KGa) for NOx range from 0.003 to 0.012 1/s and are comparable to previous studies. The results of a life cycle analysis indicate that the NOx removal rate, nitric acid recycling rate, and copper recovery rate are 85%, 80%, and 100%, respectively, reducing the environmental impact on the ecosystem, human health, and resource depletion by 10% compared to a scenario with no NOx removal.

A computer vision-based system for real-time component identification from waste printed circuit boards

With an exponential increase in consumers' need for electronic products, the world is facing an ever-increasing economic and environmental threat of electronic waste (e-waste). To minimize their adverse effects, e-waste recycling is one of the pivotal factors that can help in minimizing the environmental pollution andto increase recovery of valuable materials. For instance, Printed Circuit Boards (PCBs), while they have several valuable elements, they are hazardous too; and therefore, they form a large chunk of e-waste being generated today. Thus, in recycling PCBs, Electronic Components (ECs) are segregated at first, and separately processed for recovering key elements that could be re-used. However, in the current recycling process, especially in developing nations, humans manually screen ECs, which goes on to affect their health. It also causes losses of valuable materials. Therefore, automated solutions need to be adopted for both to classify and to segregate ECs from waste PCBs. The study proposes a robust EC identification system based on computer vision and deep learning algorithms (YOLOv3) to automate sorting process which would help in further processing. The study uses a publicly available dataset, and a PCB dataset which reflect challenging recycling environments like lighting conditions, cast shadows, orientations, viewpoints, and different cameras/resolutions. The outcome of YOLOv3 detection model based on training of both datasets presents satisfactory classification accuracy and capability of real-time competent identification, which in turn, could help in automatically segregating ECs, while leading towards effective e-waste recycling.

Rapid Fabrication of High-Resolution Flexible Electronics via Nanoparticle Self-Assembly and Transfer Printing

Printed electronic technology serves as a key component in flexible electronics and wearable devices, yet achieving compatibility with both high resolution and high efficiency remains a significant challenge. Here, we propose a rapid fabrication method of high-resolution nanoparticle microelectronics via self-assembly and transfer printing. The tension gradient-electrostatic attraction composite-induced nanoparticle self-assembly strategy is constructed, which can significantly enhance the self-assembly efficiency, stability, and coverage by leveraging the meniscus Marangoni effect and the electric double-layer effect. The close-packed nanoparticle self-assembly layer can be rapidly formed on microstructure surfaces over a large area. Inspired by ink printing, a transfer printing strategy is further proposed to transform the self-assembly layer into conformal micropatterns. Large-area, high-resolution (2 μm), and ultrathin (1 μm) nanoparticle microelectronics can be stably fabricated, yielding a significant improvement over fluid printing methods. The unique deformability, recoverability, and scalability of nanoparticle microelectronics are revealed, providing promising opportunities for various academic and real applications.

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.

Facile path for copper recovery from waste printed circuit boards via mechanochemical approach

Recycling copper (Cu⁰) from waste printed circuit boards (PCBs) is a prevalent challenge. Here, we propose a new pathway and reveal mechanisms for recovering Cu⁰ from waste PCBs via a mechanochemical approach. The successful application of mechanical force avoids using inorganic acid in the Cu⁰ recovery process. Our work demonstrates that ferric chloride (FeCl₃) was superior to ferric sulfate and ferric nitrate as a solid-phase reagent for Cu⁰ recovery due to chloride complexation. Under the induction of mechanical force, the Cu⁰ in the waste PCBs was oxidized by Fe³⁺ and complexed by Cl^¯ to form a meta-stable cuprous chloride, which was susceptible to leaching in an acidic liquid-phase system constructed by hydrolysis of ferric salt. Further mechanism analysis reveals that in the mechanochemical solid-phase reaction, Cu⁰, metallic impurities, metal oxides, and carbon materials from waste PCBs could also reduce Fe³⁺ to Fe²⁺. The optimum conditions for Cu⁰ recovery from waste PCB powder with FeCl₃ as a solid-phase reagent were: rotational speed of 500 rpm, Cu⁰:Fe³⁺ molar ratio of 1:20, and reaction time of 120 min, achieving the highest recovery of 99.6 wt%. This study presents a facile path for Cu⁰ recovery from waste PCBs for resource circulation.

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.

Urban mining of obsolete computers by manual dismantling and waste printed circuit boards by chemical leaching and toxicity assessment of its waste residues

Waste residues and acidic effluents (post-processing of E-waste) released into the local surroundings cause perilous environmental threats and potential risks to human health. Only limited research and information are available toward the sustainable management of waste residues generated post resource recovery of E-waste components. In the present study, the manual processing of obsolete computer (keyboard, monitor, CPU, and mouse) and chemical leaching of waste printed circuit boards (WPCBs) (motherboard, hard drive, DVD drive, and power supply) were performed for urban mining. The toxicity characteristics of typical pollutants in the residues of the WPCBs (post chemical leaching) were studied by toxicity characteristics leaching procedure (TCLP) test. Manual dismantling techniques resulted in an efficient urban mining concept with an overall average profit estimation of INR 2513.73/US$ 34.59. The chemical leaching of WPCBs showed a high concentration of metal leaching like Cu (229662 ± 575.3 mg/kg) and Pb (36785.67 ± 13.07 mg/kg) in the motherboard after stripping epoxy coating. The toxicity test revealed that the concentration of Cu (245.746 ± 0.016 mg/l) in the treated waste residue and Cu (430.746 ± 0.0015 mg/l) and Pb (182.09 ± 0.0035 mg/l) in the non-treated waste residue exceeded the threshold limit. The concentrations of other elements As, Cd, Co, Cr, Ag, Mn, Zn, Ni, Fe, Se, and In were within the permissible limit. Hence, the waste residue stands non-hazardous except Cu and Pb. Stripping out the epoxy coating of WPCBs enhances the metal leaching concentrations. The study highlighted that efficient and appropriate E-waste urban mining has immense potential in tracing the waste scrap into secondary resources. This study also emphasized that the final processed waste residue (left unattended or discarded due to lack of appropriate skill and technology) can be taken into consideration and exploited for value-added materials.

E-waste management and its effects on the environment and human health

Challenges in managing electronic waste (E-waste) arise from a lack of technical skills, poor infrastructure, inadequate financial support, and inactive community engagement. This study provides a systematic review of efforts to overcome these challenges in the context of inappropriate recycling protocols of E-waste and their toxic effects on human health and the environment. An inventory of end-of-life electronic products, which can be established through the creation of an environment friendly regulatory regime for recycling, is essential for the proper control of E-waste. An approach has been articulated to help implement effective management of E-waste in both developed and developing countries. Enforcement of systematic management measures for E-waste in developing countries coupled with best practices is expected to minimize adverse impacts while helping maintain a sustainable and resilient environment.

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.

Estimating Recycling Return of Integrated Circuits Using Computer Vision on Printed Circuit Boards

The technological growth of the last decades has brought many improvements in daily life, but also concerns on how to deal with electronic waste. Electrical and electronic equipment waste is the fastest-growing rate in the industrialized world. One of the elements of electronic equipment is the printed circuit board (PCB) and almost every electronic equipment has a PCB inside it. While waste PCB (WPCB) recycling may result in the recovery of potentially precious materials and the reuse of some components, it is a challenging task because its composition diversity requires a cautious pre-processing stage to achieve optimal recycling outcomes. Our research focused on proposing a method to evaluate the economic feasibility of recycling integrated circuits (ICs) from WPCB. The proposed method can help decide whether to dismantle a separate WPCB before the physical or mechanical recycling process and consists of estimating the IC area from a WPCB, calculating the IC’s weight using surface density, and estimating how much metal can be recovered by recycling those ICs. To estimate the IC area in a WPCB, we used a state-of-the-art object detection deep learning model (YOLO) and the PCB DSLR image dataset to detect the WPCB’s ICs. Regarding IC detection, the best result was obtained with the partitioned analysis of each image through a sliding window, thus creating new images of smaller dimensions, reaching 86.77% mAP. As a final result, we estimate that the Deep PCB Dataset has a total of 1079.18 g of ICs, from which it would be possible to recover at least 909.94 g of metals and silicon elements from all WPCBs’ ICs. Since there is a high variability in the compositions of WPCBs, it is possible to calculate the gross income for each WPCB and use it as a decision criterion for the type of pre-processing.

Sampling waste printed circuit boards: Achieving the right combination between particle size and sample mass to measure metal content

The current worldwide expansion of waste PCB (WPCB) deposits represents both a pressing environmental issue and an economic opportunity, fostering the development of numerous recycling processes across the world. An important input for designing such processes is the metallic content of WPCBs, which is assayed by grinding and leaching samples taken from the stack of WPCBs to be recycled. The content values come with substantial uncertainties, arising mainly from the uneven distribution of the metals within the structure of WPCBs. This study aims to quantify the effects on these uncertainties of the particle size, the mass of the sample digested and the number of digestion replicates. It focused on the abundance of six metals in WPCBs: Cu, Fe, Zn, Pb and Ni, and also Co, which is a critical element for the EU. A batch of 485 kg of WPCBs was put through several shredding and splitting steps to produce three fractions: one shredded to 2 mm, and two ground to 750 μm and 200 μm. From each sample, 16 samples of 0.5 g, 2 g or 5 g were digested in hot aqua regia. Bootstrapping of the results allowed the error around the mean content to be estimated, for each metal and for all the experimental conditions. Considering the largest sample masses and three replicated digestions, the uncertainties for Zn (resp. Ni) were reduced from 35% to 10% (resp. from 70% to 10%) when the particle size was reduced from 2 mm to 200 μm.

Mechano-microbial systems: An ecofriendly approach for copper bioleaching from waste printed circuit board

Waste printed circuit board (PCB) is attracting serious concerns because the recycling of its valuable metallic portion is made difficult by the existence of hazardous substances. The objective of the present study was to develop a simplified approach for copper bioleaching from waste PCB. In this context, we intended mechano-microbial systems symbolized as SET-I (spore suspension + potato dextrose broth medium + waste PCB powder), SET-II (pre-cultured until the logarithmic phase, without waste PCB powder), and SET-III (fungal metabolites produced at stationary phase). The results of bioleaching studies showed that the developed method achieved the highest copper leaching of 85% by the SET-III approach. This study provides an insight for bioleaching copper from waste PCB. Furthermore, this approach can be established as an ecofriendly method for copper bioleaching by using an integrated system.

A Comprehensive Study on The Accelerated Weathering Properties of Polypropylene-Wood Composites with Non-Metallic Materials of Waste-Printed Circuit Board Powders

In this study, non-metallic materials of waste-printed circuit board powders (WPCBP) were successfully used as reinforcing filler to produce polypropylene (PP)–wood composites, and their effect on the weathering properties of PP composites were fully evaluated via oxidation induction time (OIT), attenuated total reflectance Fourier-transform infrared spectroscopy (ATR-FTIR), differential scanning calorimetry, vicat softening point (VST), scanning electron microscopy, and mechanical properties analysis. The OIT analysis confirmed that the anti-thermal oxidative aging properties of PP–wood composites were decreased with the loading of WPCBP. Apart from that, the PP composite, reinforced with 30 wt.% of WPCBP, exhibited the highest value of active energy, which suggests that it is more sensitive to temperature and oxygen when compared with other PP composites. The mechanical properties analysis revealed that neat PP exhibited the poorest weathering properties after being subjected to UV exposure, and its retention rate of tensile strength and notched impact strength were only 70.6% and 59.6%, respectively, while WPCBP and wood flour (WF) could efficiently improve the retention rates of the mechanical properties of the PP composites when subjected to UV exposure. The visual appearance of the PP composites after being subjected to UV exposure showed more and smaller cracks with the loading of WPCBP and WF. The ATR-FTIR results revealed that the carbonyl index increased for all the weathered samples, and the more WPCBP was added into the PP composites led to a higher carbonyl index value, which might be due to the multivalent transition metals in WPCBP, which accelerate the photo-oxidation of the PP composites. The VST results show that both WPCBP and WF can effectively enhance the heat deformation resistance of the PP composites that have been subjected to UV exposure.

A novel method for the removal of epoxy coating from waste printed circuit board

The printed circuit board, which is the heart of all electronic devices, is a rich source of metal, which could act as a future resource. Bioleaching, a biological treatment, would be an appropriate method for the environmentally sound management of e-waste. Various strippers are used to remove the epoxy coating and it is harmful to remove the epoxy coating with those solvents and salts in the open because of the presence of brominated flame retardants on the surface of the printed circuit board, which leads to serious health issues. An alternate process is required to remove the epoxy coating thereby enhancing the bioleaching process. Sonication is the process of applying sound energy to agitate particles in a solvent bath. The combined process of sonication and solvent stripping in a closed environment could decrease the time for stripping the epoxy coating. An attempt has been made to optimise the stripping agent for the removal of epoxy coating and from the experiment it was found that bath sonication could easily remove the epoxy coating from the waste printed circuit board with no emission of toxic gases. An optimum time of 5 min was enough for the stripping process prior to the soak time of 8 h at 5 N NaOH solution, while a longer time and high concentration of chemicals would be required to remove the epoxy coating with usual methods.

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.

Assessing resident awareness on e-waste management in Bangalore, India: a preliminary case study

The generation of e-waste has increased significantly in India, and the informal recycling of e-waste has adverse effects on environment and public health. In this article, the E-waste management is evaluated in accordance from the resident's awareness perspective in Bangalore city, India. The survey data revealed that about 58% male and 42% female responded and 35% of the participants belong to age range between 18 and 25 years. About 60% of respondent's education level was either graduate or post graduate, 27% high school to higher school, 10% higher educated (> post graduate), and 3% primary to middle. Only 30% of the respondents were confident with e-waste rules and regulation, while 39% of the respondents were of very little information. Indian e-waste management has been improving for the last few years and it continues to develop. Therefore, the findings can be valuable for better understanding the resident's awareness for e-waste management and also need to promote the environmentally sound management of e-waste in Bangalore, India.