Recycling of printed circuit boards (PCBs) to generate enriched rare metal concentrate

The effect of particle geometry (size & shape) on the recovery of gold and copper metallic particles from end-of-life random access memory cards by flotation

Since Random Access Memory (RAM), one of the main parts of computers contains a remarkable quantity of precious metals, applying flotation at the pre-concentration stage to recycle these metals can result in a more cost-effective, user-friendly, and environmentally friendly process compared to direct chemical methods. While the significance of physical characteristics like particle size and shape in the flotation process is well established, the impact of particle shape in the flotation process utilized in the recycling of end-of-life (EoL) RAMs hasn't yet been thoroughly investigated. To fill this gap, a two-stage coarse flotation approach is used for the selective recovery of plastic and valuable metallic particles for sustainable development. The particle geometry of metallic particles recovered by flotation was characterized by axis measurement on the images by optical microscope that allows us to distinguish particles of different sizes and colors that make up the sample and evaluated in terms of particle size distribution (PSD), elongation (E) and roundness (R) parameters. The results showed that after the plastic fraction is effectively removed, it is possible to produce pre-concentrated products with high metal content (more than 50 % Cu content at the 1st stage and 1800 g/t Au content at the 2nd stage using 900 g/t KAX) in an economical and environmentally friendly way. Thus, it was concluded that the gold and copper metallic particles in the reduced-size EoL RAM cards could be easily floated by attaching them to the air bubble with the help of the collector, thanks to their flat shape.

Potential and current practices of recycling waste printed circuit boards: A review of the recent progress in pyrometallurgy

Over the last few decades, a substantial amount of e-waste including waste printed circuit boards (WPCBs) has been produced and is accumulating worldwide. More recently, the rate of production has increased significantly, and this trend has raised some serious concerns regarding the need to develop viable recycling methods. The presence of other materials in the WPCBs, such as ceramics and polymers, and the multi-metal nature of WPCBs all contribute to the increased complexity of any recycling process. Among the viable techniques, pyrometallurgy, with the inherent ability to process the waste independent of its composition, is a promising candidate for both rapid and large-scale treatment. In the present study, firstly, the principles of the pyrometallurgical methods for WPCB recycling are discussed. Secondly, the different unit operations of thermochemical pretreatment including incineration, pyrolysis, and molten salt processing are reviewed. Thirdly, the smelting processes for the recovery of metals from WPCBs, as well as the issues surrounding slag formation and subsequent treatment are explained. Fourthly, alternative methods for the recovery of polymers and ceramics, in addition to metal recycling, are elucidated. Fifthly, emission control techniques and the potential for energy recovery are evaluated.

Precious and critical metals from wasted LED lamps: characterization and evaluation

LED lamps already conquered the market of general lighting and are expected to generate a substantial stream of e-waste in the coming years. The challenge of recycling LED lamps have emerged, and it is essential to address both environmental and economic aspects to achieve a circular economy. LED lamps contain precious and critical metals, which can be found in electrical components and in the LED itself, making them a prospective waste for recycling initiatives. However, data about the concentration and distribution of these metals in the LED lamp's components are still scarce and uncertain. This work aims to characterise the various components of different brands of LED lamps to provide novel data on the precious and critical metals' amounts. Gold and silver were found in all brands of lamp, and we highlight the occurrence of gold in all analysed components, in concentrations between 0.01% and 0.07%, which is relevant to the economic viability of future recycling routes (gold and silver can contribute with USD 4340.00 per ton of LED lamps). The critical metals gallium, yttrium, and cerium were found in LEDs, while cobalt, barium, gallium, antimony, and manganese were found in printed circuit boards (PCBs). Additionally, the elements lead, cadmium, and arsenic were characterised due to their association with environmental and human toxicity.

Review on Zigzag Air Classifier

The zigzag (ZZ) classifier is a sorting and classification device with a wide range of applications (e.g., recycling, food industry). Due to the possible variation of geometry and process settings, the apparatus is used for various windows of operation due to the specifications of the separation (e.g., cut sizes from 100 µm to several decimetres, compact and fluffy materials as well as foils). Since the ZZ classifier gains more and more interest in recycling applications, it is discussed in this paper, with regards to its design, mode of operation, influencing parameters and the research to date. Research on the ZZ-classifier has been ongoing on for more than 50 years and can be divided into mainly experimental studies and modelling approaches.

Recovery of high-grade copper from metal-rich particles of waste printed circuit boards by ball milling and sieving

In this paper, a method of ball milling and sieving is proposed for recovery of high-grade copper from waste printed circuit boards (WPCBs). The effects of the milling time on the metals grade and recovery of the Cu, Sn and Pb during mechanical treatment were investigated. The results showed that, after 3 cycles of ball milling and sieving, the content of Cu was enriched to 94.72 wt.% from the initial 74.22 wt.% with a high recovery rate of 86.78%. Moreover, the contents of Sn and Pb were enriched to 28.27 wt.% and 18.86 wt.% from 10.13 wt.% and 6.63 wt.% in the by-products, respectively. However, excessive grinding occurred when the milling time was longer than 3 h and led to a sharp decrease in Cu recovery. The X-ray diffraction (XRD) patterns indicated that the metal phases mainly comprised pure Cu, Sn, Pb in the WPCB particles, while a Cu-Sn alloy was formed during the milling process, and the Cu-Sn alloy was also enriched in the tailings. The results presented here establish that ball milling and sieving is an alternative approach to recovering high-grade copper from WPCBs.

Impact of Grinding of Printed Circuit Boards on the Efficiency of Metal Recovery by Means of Electrostatic Separation

This paper analyses the impact of the method of grinding printed circuit boards (PCBs) in a knife mill on the efficiency and purity of products obtained during electrostatic separation. The separated metals and plastics and ceramics can be used as secondary raw materials. This is in line with the principle of circular economy. Three different screen perforations were used in the mill to obtain different sizes of ground grains. Moreover, the effect of cooling the feed to cryogenic temperature on the final products of separation was investigated. The level of contamination of the concentrate, intermediate, and waste obtained as a result of the application of fixed, determined electrostatic separation parameters was assessed using ICP-AES, SEM–EDS, XRD, and microscopic analysis as well as specific density. The yields of grain classes obtained from grinding in a knife mill were tested through sieve analysis and by using a particle size analyser. The test results indicate that using a knife mill with a 1 mm screen perforation along with cooling the feed to cryogenic temperature significantly improves the efficiency of the process. The grinding products were characterised by the highest release level of the useful substance—metals in the free state. The purity of the concentrate and waste obtained from electrostatic separation was satisfactory, and the content of the intermediate, in which conglomerates of solid metal–plastic connections were present, was very low. The yield of concentrate and waste amounted to 26.2% and 71.0%, respectively. Their purity, reflected in the content of the identified metals (valuable metals), was at the level of 93.3% and 0.5%, respectively. In order to achieve effective recovery of metals from PCBs by means of electrostatic separation, one should strive to obtain a feed composed of grains <1000 μm and, optimally, <800 μm.

Enhanced flotation efficiency of metal from waste printed circuit boards modified by alkaline immersion

Efficient recycling of waste printed circuit boards by flotation has become a research focus. In this study, waste printed circuit boards were treated by alkaline immersion to enhance the flotation efficiency. Firstly, the SEM-EDS analysis of the crushed products shown that metal and nonmetal were completely liberated in the -0.25 mm fraction. When the printed circuit boards were modified by alkaline immersion, the recovery of metal increased from 64.34% to 72.35%. Further, the mixture of metal and nonmetal at the edge of nonmetal was discovered by EPMA. This was the cause of metal loss during the flotation process. Secondly, by adjusting the alkaline immersion time and pH value, a good flotation effect was achieved at 40 min alkaline immersion time and the pH = 11. Meanwhile, the XPS analysis of nonmetal found that the intensity of the OH peak was significantly enhanced, while the intensity of the O peak was evidently decreased. The change of the resin molecular structure indicated that the O linked to the benzene ring was broken under the action of alkaline immersion, resulting a free bond was generated on the benzene ring. This made the free OH adsorb to the free bond. This conduct promoted the dispersion of nonmetal in the slurry due to the increased nonmetal surface energy and metal hydrophilicity. Thus, this study provides a new route to improve the flotation efficiency of waste printed circuit boards.

Copper and Antimony Recovery from Electronic Waste by Hydrometallurgical and Electrochemical Techniques

A strategy for the efficient recovery of highly pure copper and antimony metals from electronic waste (e-waste) was implemented by the combination of hydrometallurgical and electrochemical processes. The focus is on copper recovery as the main component in the leached solution, whereas the antimony recovery process was established as a purification step in order to achieve a highly pure copper deposit. The strategy includes mechanical methods to reduce the size of the wasted printed circuit boards to enhance the efficiency of antimony and copper lixiviation via ferric chloride in acidic media (0.5 M HCl) followed by an electrowinning process. In order to establish the best parameters for copper electrowinning, the leached solution was characterized by cyclic voltammetry and cathodic polarization. Then, an electrochemical reactor with a rotating cylinder electrode was used to evaluate the copper concentration decay, the cathodic current efficiency, the specific energy consumption, and mass-transfer coefficient. Furthermore, antimony was recovered via precipitation by a pH modification in accordance with the Pourbaix diagram. Under this methodology, two valuable products from the e-waste were recovered: a 96 wt % pure copper deposit and 81 wt % pure antimony precipitate. The strategy for recovery of other metal ions, such as lead, present in the e-waste at high concentrations will be reported in further works.

Gold recovery from shredder light fraction of E-waste recycling plant by flotation-ammonium thiosulfate leaching

This paper describes the recovery of gold (Au) from shredder light fraction (SLF) of a recycling plant by flotation and leaching. SLF is typically sent to landfills as waste, but it still contains substantial amounts of Au, and other metals like Cu and Fe. The SLF sample used in this study contains 0.003% of Au, 12% of Cu, and 10% of Fe. Flotation results showed that over 99% of Au and 50% of combustibles were recovered in froth while most of the base metals were recovered in tailing. SEM-EDX of froth products indicates that Au floated via two mechanisms: (1) flotation of Au-plated plastic particles, and (2) agglomeration of fine Au particles together with plastic particles due to kerosene-induced hydrophobic-hydrophobic interactions followed by the flotation of these agglomerated particles. Combustibles in froth/tailing were analyzed by ATR-FTIR, and the results showed that plastics in the froth were mostly sulfonated polystyrene (PS) and acrylonitrile butadiene styrene (ABS) while those in tailing were polyurethane (PU) and polyethylene terephthalate (PET). Contact angle measurements of plastic particles suggest that PS and ABS are more hydrophobic than PU and PET. Most of the base metals in the tailing had either bent or twisted shapes because they were mostly made up of wires. In flotation, these large and heavy particles are unaffected by bubbles and simply sink. Leaching results using ammonium thiosulfate solutions showed that Au extraction increased from 33 to 51% after flotation.

Waste Printed Circuit Board (PCB) Recycling Techniques

With the development of technologies and the change of consumer attitudes, the amount of waste electrical and electronic equipment (WEEE) is increasing annually. As the core part of WEEE, the waste printed circuit board (WPCB) is a dangerous waste but at the same time a rich resource for various kinds of materials. In this work, various WPCB treatment methods as well as WPCB recycling techniques divided into direct treatment (landfill and incineration), primitive recycling technology (pyrometallurgy, hydrometallurgy, biometallurgy and primitive full recovery of NMF-non metallic fraction), and advanced recycling technology (mechanical separation, direct use and modification of NMF) are reviewed and analyzed based on their advantages and disadvantages. Also, the evaluation criteria are discussed including economic, environmental, and gate-to-market ability. This review indicates the future research direction of WPCB recycling should focus on a combination of several techniques or in series recycling to maximize the benefits of process.

Recovery of metallic concentrations from waste printed circuit boards via reverse floatation

Efficient disposal of waste printed circuit boards (PCBs) is favorable toward recovering valuable components and reducing pollution. Reverse floatation was used to recover metallic concentrations from waste PCBs. Basic properties and mineralogical characteristics of raw PCBs were tested and analyzed. Results indicated that the grade of metallic concentrations declined as the size fraction of PCBs decreased. The major metallic elements found in PCBs were Cu, Pb, and Sn, as well as trace elements were also found in fine PCB particles. Kerosene and terpenic oil were used as the collector and frother in the floatation experiments. The effects of various operational factors, including the feeding concentration, aeration rate, and agitation speed of floatation machine, on the floatation performance of -0.25mm PCBs were experimentally studied to determine optimal range. The floatation results suggested that the yield of sinks and grade of metallic concentrations diminished significantly with the decrease of size fraction of PCBs. The maximum yields of sinks and highest grades of metallic concentrations were 48.72% and 16.86%, 47.96% and 14.61%, 44.36% and 8.81%, with the optimum recoveries of metallic concentrations of 94.69%, 90.06%, and 75.96% for size fractions of 0.125-0.25mm, 0.074-0.125mm, and -0.074mm PCBs, respectively. The recovery efficiency of metallic concentrations declined as the size fraction decreased. The efficient overall recovery performance of metallic concentrations from waste PCBs was obtained via reverse floatation. This study provides an alternative approach for disposing waste PCBs.